Mattress assemblies having nested, zipperless mattress ticking assemblies

ABSTRACT

Mattress assemblies include a mattress core assembly and a nested, zipperless mattress ticking assembly for covering the mattress core assembly and a nested, zipperless mattress ticking assembly for covering the mattress core assembly. The nested, zipperless mattress ticking assembly includes an upper mattress ticking assembly having a top side extending over a top side of the mattress core assembly and a peripheral portion extending over a portion of the peripherally-extending side of the mattress core assembly, and a lower mattress ticking assembly having a bottom side extending over the bottom side of the mattress core assembly and a peripheral portion extending over a portion of the peripherally-extending side of the mattress core assembly. The peripheral portions of the upper and lower mattress ticking assemblies overlap each other along the peripherally-extending side of the mattress core assembly. The mattress assembly meets the flammability standards of the 16 CFR 1633.

CLAIM TO PRIORITY

This application claims the benefit of U.S. Provisional PatentApplication No. 62/479,098, filed Mar. 30, 2017, entitled “MattressAssemblies Having Nested, Zipperless Mattress Ticking Assemblies”, theentire contents of which is hereby incorporated herein by reference.

FIELD OF THE DISCLOSURE

The present disclosure relates generally to mattresses, and moreparticularly to nested, zipperless mattress ticking assemblies, andmattresses employing the same.

BACKGROUND

According to the International Sleep Products Association (“ISPA”) 2015Industry Report, the entire subject matter of which is incorporatedherein by reference, U.S. mattress producers shipped nearly 39 millionunits (mattresses and foundations) in 2015, an increase of 4.5% over2014 and the sixth consecutive yearly unit increase since 2010. Averageunit prices increased by 2.2% in 2015.

Mattresses and foundations are typically sold as sets. However, moremattresses are sold annually than foundations. Some mattresses are soldas replacements for existing mattresses (without a new foundation) orare for use in platform beds or other beds that do not require afoundation. ISPA estimated that the total number of U.S. conventionalmattress shipments was 20.9 million in 2014, and 22.1 million in 2015.These estimates do not include futons, crib mattresses, juvenilemattresses sleep sofa inserts, or hybrid water mattresses. These“non-conventional” sleep surfaces are estimated to comprise about 10percent of total annual shipments of all sleep products. The value ofconventional mattress and foundation shipments in 2015, according toISPA, was $6.72 and $1.31 billion respectively, compared to $6.24 and$1.28 billion respectively in 2014.

The expected useful life of mattresses can vary substantially, with moreexpensive models generally experiencing the longest useful lives.Industry sources recommend replacement of mattresses after 10 to 12years.

The ISPA also provides data on the customary sizes of mattresses and theannual sales attributable to each size of mattress. The typical sizesand sales are as follows as show in Table 1:

TABLE 1 Mattress 2014 % of 2015 % of Size Dimensions Total Total Twin38″ × 74.5″ 20.2% 19.0% Twin XL 38″ × 79.5″  2.1%  2.4% Full 53″ × 74.5″16.2% 15.4% Full XL 53″ × 79.5″  0.7%  0.6% Queen 60″ × 79.5″ 40.1%40.2% King 76″ × 79.5″ 15.2% 16.7% Cal King 72″ × 84″  1.8%  1.7% OddSizes Varies  3.7%  4.0%

Mattresses are generally classified into two general types by theInternational Sleep Products Association (ISPA): Innerspring andNon-Innerspring. The ticking assemblies of innerspring mattresses aregenerally permanently closed with sewn seams and according to ISPA thissegment of the industry accounts for more than 85% of unit sales and 73%of dollar sales in 2015. These designs preclude entirely theend-consumers ability to adjust or even replace inner materialcomponents of the mattress in the event of material failures, wear ordesire to alter the comfort and feel of the mattress.

Only 15% of mattress unit sales and 27% of mattress dollar sales areclassified by ISPA as Non-Innerspring and not all of these designsprovide the end-user with the ability to access the interior elements ofthe mattress by means of a ticking assembly that allows opening andclosing of the ticking assembly through use of a zipper. Thesemattresses are typically compressed, sealed in plastic to hold thecompression, rolled and then stuffed in packaging that permits themattresses to be shipped by courier services such as United ParcelService, Federal Express or DHL. The consumer is responsible forunpackaging the mattress and placing it in their desired sleeping space.

SUMMARY

Shortcomings of the prior art are overcome and additional advantages areprovided through the provision, in one embodiment, of a mattressassembly which includes, for example, a mattress core assembly and anested, zipperless mattress ticking assembly for covering the mattresscore assembly and a nested, zipperless mattress ticking assembly forcovering the mattress core assembly. The mattress core assembly includestop side, a bottom side, and a peripherally-extending side disposedbetween the top side and the bottom side. The nested, zipperlessmattress ticking assembly includes an upper mattress ticking assemblyand a lower mattress ticking assembly. The upper mattress tickingassembly includes a top side extending over the top side of the mattresscore assembly and a peripheral portion extending over a portion of theperipherally-extending side of the mattress core assembly. The lowermattress ticking assembly includes a bottom side extending over thebottom side of the mattress core assembly and a peripheral portionextending over a portion of the peripherally-extending side of themattress core assembly. The peripheral portions of the upper and lowermattress ticking assemblies overlap each other along theperipherally-extending side of the mattress core assembly. The mattressassembly meets the flammability standards of the 16 CFR 1633.

In another embodiment, a mattress assembly is provided. The mattressassembly includes, for example, a mattress core assembly having a topside, a bottom side, and a peripherally-extending side disposed betweenthe top side and the bottom side, an upper mattress ticking assemblycomprising a top side extending over the top side of the mattress coreassembly and a peripheral portion extending over theperipherally-extending side of the mattress core assembly, and a bottomside disposed under a portion of the bottom side of the mattress core,and wherein the mattress assembly meets the flammability standards ofthe 16 CFR 1633.

In another embodiment, a method for forming a mattress assembly isprovided. The method includes, for example, providing a mattress coreassembly having a top side, a bottom side, and a peripherally-extendingside disposed between the top side and the bottom side, positioning anested, zipperless mattress ticking assembly comprising an uppermattress ticking assembly and a lower mattress ticking assembly over themattress core assembly, and portions of the upper mattress tickingassembly and the lower mattress ticking assembly overlapping each other.The mattress assembly meets the flammability standards of the 16 CFR1633.

BRIEF DESCRIPTION OF THE DRAWINGS

The subject matter which is regarded as the disclosure is particularlypointed out and distinctly claimed in the concluding portion of thespecification. The disclosure, however, may best be understood byreference to the following detailed description of various embodimentsand the accompanying drawings in which:

FIG. 1 is a perspective view of a mattress assembly and mattressfoundation according to an embodiment of the present disclosure.

FIG. 2 is a cross-sectional view of the mattress assembly having a corehaving a single cushioning element enclosed by a nested, zipperlessmattress ticking assembly taken along line 2-2 of FIG. 1 according to anembodiment of the present disclosure.

FIG. 3 is a cross-sectional view of a mattress assembly having a corehaving a single cushioning element enclosed by a nested, zipperlessmattress ticking assembly according to an embodiment of the presentdisclosure.

FIG. 4 is a cross-sectional view of a mattress assembly having a corehaving a two cushioning elements enclosed by a nested, zipperlessmattress ticking assembly according to an embodiment of the presentdisclosure.

FIG. 5 is a cross-sectional view of a mattress assembly having a corehaving a two cushioning element enclosed by a nested, zipperlessmattress ticking assembly according to an embodiment of the presentdisclosure.

FIG. 6 is a cross-sectional view of a mattress assembly having a corehaving multiple cushioning elements enclosed by a nested, zipperlessmattress ticking assembly according to an embodiment of the presentdisclosure.

FIG. 7 is a cross-sectional view of a mattress assembly having a corehaving multiple cushioning elements enclosed by a nested, zipperlessmattress ticking assembly according to an embodiment of the presentdisclosure.

FIG. 8 is a cross-sectional view of a mattress assembly having a core ofmultiple cushioning elements enclosed by a nested, zipperless mattressticking assembly according to an embodiment of the present disclosure.

FIG. 9 is a perspective view of a lower portion of the nested,zipperless mattress ticking assembly according to an embodiment of thepresent disclosure.

FIG. 10 is a perspective view of a lower portion of a nested, zipperlessmattress ticking assembly according to an embodiment of the presentdisclosure.

FIG. 11 is a perspective view from above an upper portion of the nested,zipperless mattress ticking assembly according to an embodiment of thepresent disclosure.

FIG. 12 is a perspective view of an underside of an upper portion of anested, zipperless mattress ticking assembly according to an embodimentof the present disclosure.

FIG. 13 is a perspective view of an underside of an upper portion of anested, zipperless mattress ticking assembly according to an embodimentof the present disclosure.

FIG. 14 is a cross-sectional view from either a head or a foot of amattress assembly having separate upper mattress core assemblies atop asingle lower mattress core assembly, the core assemblies being encloseda nested, zipperless mattress ticking assembly according to anembodiment of the present disclosure.

FIG. 15 is a cross-sectional view from either a head or a foot of amattress assembly having a single upper mattress core assembly atop aseparate lower mattress core assemblies, the core assembly beingenclosed by a nested, zipperless mattress ticking assembly according toan embodiment of the present disclosure.

FIG. 16 is a cross-sectional view from either a head or a foot of amattress assembly having separate upper mattress core assemblies atop aseparate lower mattress core assemblies, the core assemblies beingenclosed by a nested, zipperless mattress ticking assembly according toan embodiment of the present disclosure.

FIG. 17 is a cross-sectional view of a portion of a top side of an uppermattress ticking assembly according to an embodiment of the presentdisclosure extendable over a top side of a mattress core assembly.

FIG. 18 is a cross-sectional view of a portion of a top side of an uppermattress ticking assembly according to an embodiment of the presentdisclosure extendable over a top side of a mattress core assembly.

FIG. 19 is a cross-sectional view of a portion of a top side of an uppermattress ticking assembly according to an embodiment of the presentdisclosure extendable over a top side of a mattress core assembly.

FIG. 20 is a cross-sectional view of a portion of a top side of an uppermattress ticking assembly according to an embodiment of the presentdisclosure extendable over a top side of a mattress core assembly.

FIG. 21 is a cross-sectional view of a portion of a nested, zipperlessmattress ticking assembly according to an embodiment of the presentdisclosure with portions of an upper mattress ticking assembly and alower mattress ticking assembly being physically attachable orconnectable via buttons or snaps.

FIG. 22 is a cross-sectional view of a portion of a nested, zipperlessmattress ticking assembly according to an embodiment of the presentdisclosure with portions of an upper mattress ticking assembly and alower mattress ticking assembly being physically attachable orconnectable by being sewn or stitched together.

FIG. 23 is a cross-sectional view of a portion of a nested, zipperlessmattress ticking assembly according to an embodiment of the presentdisclosure with portions of an upper mattress ticking assembly and alower mattress ticking assembly being physically attachable orconnectable via hook-and-loop fasteners.

FIG. 24 is a cross-sectional view of a mattress core assembly having aplurality of core elements and a fire barrier interliner according to anembodiment of the present disclosure.

DETAILED DESCRIPTION

The present disclosure and certain features, advantages, and detailsthereof, are explained more fully below with reference to thenon-limiting embodiments illustrated in the accompanying drawings.Descriptions of well-known materials, fabrication tools, processingtechniques, etc., are omitted so as to not unnecessarily obscure thedisclosure in detail. It should be understood, however, that thedetailed description and the specific examples, while indicatingembodiments of the present disclosure, are given by way of illustrationonly, and are not by way of limitation. Various substitutions,modifications, additions and/or arrangements within the spirit and/orscope of the underlying concepts will be apparent to those skilled inthe art from this disclosure. Reference is made below to the drawings,which are not drawn to scale for ease of understanding.

FIG. 1 illustrates a mattress assembly 200 supported on a mattressfoundation 100 according to an embodiment of the present disclosure. Asshown in FIG. 2, mattress assembly 200 may include a mattress coreassembly 210 having a single core or cushioning element enclosed by anested, zipperless mattress ticking assembly 230 in accordance with anembodiment of the present disclosure. As described and illustratedherein, the various embodiments of the nested, zipperless mattressticking assembly provide an outermost layer of fabric, fabrics and/orrelated material that encloses a mattress core assembly forming amattress assembly or mattress pad. The various embodiments described andillustrated herein of the nested, zipperless mattress ticking assemblymay be formed from the various material used for forming a tickingdisclosed herein. The upper and lower mattress tickings of the variousembodiment of nested, zipperless mattress ticking assemblies accordingto the present disclosure may be releasably attachable to each other andto a mattress core assembly, partially attached to each other, orsubstantially attached to each other.

While description and illustration of the present disclosure is made tovarious embodiments of nested, zipperless ticking assemblies formattresses, the design approaches recited herein may also be found to bebeneficial in the production of articles of upholstered furniture,transportation seating or other similar cushion based articles orfurnishing systems where the end-user desires to have the ability toeasily access and modify, exchange or replace the internal materialelements of such articles or systems and the ability to easily removeand install and even launder a removable nested, zipperless tickingassembly or exterior most fabric used in the construction of thecomposite article. For example, The present disclosure provides for anested, zipperless mattress ticking assembly and a mattress made withsuch ticking assembly that is intended to complement and enhance theevolving designs of mattresses that are being engineered to becompressed, rolled and shipped directly to consumers, bypassingtraditional retail-storefront selling settings, and that additionallyare being constructed so as to provide said consumers to be able toself-modify the internal cushioning elements of the mattress.

As shown in FIG. 2, in one exemplary embodiment of the presentdisclosure, mattress assembly 200 may include single element mattresscore assembly 210 encased by a nested, zipperless ticking assembly 230.Single element mattress core assembly 210 may include a top side 212, abottom side 214, and a peripherally-extending side 216 disposed betweentop side 212 and bottom side 214.

Nested, zipperless ticking assembly 230 may include a lower or basemattress ticking assembly 240 and an upper mattress ticking assembly260. Lower mattress ticking assembly 240 includes a bottom side 244extending over bottom side 214 of mattress core assembly 210 and aperipheral portion 246 extending over a portion ofperipherally-extending side 216 of mattress core assembly 210.Peripheral portion 246 may have a peripheral edge that is disposedgenerally level with top side 212 of mattress core assembly 210. Uppermattress ticking assembly 260 includes a top side 262 extending over topside 212 of mattress assembly 210 and a peripheral portion 266 extendingover a portion of peripherally-extending side 216 of mattress coreassembly 210. Peripheral portions 246 and 266 of upper and lowermattress ticking assemblies 240 and 260 overlap each other alongperipherally-extending side 216 of mattress core assembly 210. Asexplained below, mattress assembly 200 meets the flammability standardsof the 16 CFR 1633.

The ticking assembly is defined as being nested according to the presentdisclosure in that the upper mattress ticking assembly 260 overlaps thelower or base mattress ticking assembly 240 in one or more of thevertical planar faces (the mattress “border”) of the mattressconstruction. For purposes of the embodiment depicted in FIG. 2, theoverlap is shown as being present along and across the entire height ofthe mattress border, however an overlap of at least 1 inch in themattress border is contemplated by the present disclosure. The nestednature of the present disclosure also may be satisfied if the lower orbase mattress ticking assembly 240 were disposed to the outside of theupper mattress ticking assembly 260.

The single element mattress assembly 210 may in its simplest form be ahomogenous block of polyurethane foam. The single element mattress coreassembly 210 may also be made of any variety of resilient cushioningmaterials customarily used in the construction of mattresses orupholstered furnishings. Such examples of foams or resilient cushioningmaterials can include but are not intended to be limited to latex foam;reticulated or non-reticulated visco-elastic foam (sometimes referred toas memory foam or low-resilience foam), reticulated or non-reticulatednon-visco-elastic foam; gel based foams; foams infused with graphite orother substances; high-resilience polyurethane foam; expanded polymerfoams (e.g., expanded ethylene vinyl acetate, polypropylene,polystyrene, or polyethylene); and the like. Such foams and resilientcushioning materials are contemplated for use for all possibleembodiments disclosed herein with regards to the present disclosure.

The exemplary single element mattress core assembly 210 may be anassembled composite of a plurality of different cushioning elements thatare glued, laminated or attached together to form a single unit.Utilizing different cushioning compositions or identical cushioningcompositions with varied density or Indentation Force Deflection (IFD)can yield differential feel on each panel oriented face of the coreassembly element. One iteration of the internal foam formulations is alaminated foam structure comprising foam slabs layered and attached toeach other in the following sequence: a 1″ natural latex with an IFD of14, 1″ of latex with an IFD of 19 or higher and a 2″ gel visco with anIFD range of 10-16.

Further referring to FIG. 2, this particular embodiment depicts thelower or base mattress ticking assembly 240 as covering the entirety ofthe bottom horizontal planar face (also known to those skilled in theart as the bottom panel) of the mattress core assembly and covering thefour vertical planar faces (also known as the side borders) of themattress. In this embodiment, the materials of the lower or basemattress ticking assembly 240 are not intended to transit beyond theright angle transition from the side border faces of the mattress to thetop horizontal planar face of the mattress core assembly 210.

The design of the upper mattress ticking assembly 260 may be fashionedso as to have a portion 268 of the material extend into the area atbottom panel 214 of mattress core assembly 210 from at least one of thefour vertical sides of the mattress assembly. The preferred embodimentwould be to have the upper mattress ticking assembly 260 material extendfrom all four border faces to the bottom panel of the mattress, but thisis not required. This feature permits the weight of the mattress andthose sleeping or disposed upon the mattress to assist in holding theupper mattress ticking assembly 260 in place.

The embodiments of the present disclosure is not limited to the myriadof textiles that may be used to fashion the lower or base mattressticking assembly 240. Suitable materials may be chosen from those knownto mattress manufacturers to be sufficient to withstand the use demandsand aesthetic desires of consumers.

The design approach of the exemplary embodiments recited herein usesrelatively simple, single layer or fabric textile combinations andstructures, however it is anticipated that more complicated, compositetextile structures, such as a quilted, multi-layer assembly ofdecorative fabrics and thin foam sheets or fiber-based “quilting” fabricmay be used in lieu of simple, single layer fabrics. Such textilestructures may also include non-woven backer fabrics that assist inpreparing such quilted, multi-layer assemblies and such “quiltassemblies” are well-known to the mattress manufacturing community andtheir use would not constitute a material departure from the presentinvention.

The materials for selected for use in the design of the lower or basemattress ticking assembly 240 and upper mattress ticking assembly 260may desirably incorporate textiles with elastomeric materials thatdeliver stretch and recovery properties and effectively hold theinterior elements together and deliver fit, finish and accessibilityproperties as contemplated by the present disclosure. The utilization oftextiles with elastic properties is contemplated for all subsequentlydepicted drawings and embodiments of the present disclosure.

No zippers are used in the present disclosure to attach lower or basemattress ticking assembly 240 and upper mattress ticking assembly 260 asis customary in the production of mattresses and mattress foundation andthe present embodiment is not depicted with any attachment of lower orbase mattress ticking assembly 240 to the upper mattress tickingassembly 260. It is however anticipated that a ticking assemblyaccording to the present disclosure and all embodiment depictionsrecited herein, may be fashioned where lower or base mattress tickingassembly 240 and upper mattress ticking assembly 260 are attached to oneanother by means other than a zipper, such as sewn seams, snaps, buttonsor hook and loop systems.

This specific exclusion of a zipper from the design of the presentdisclosure is carried through all following drawings and anticipatedembodiments.

The selection of material for use in these elements, as previouslyindicated, may be made from a wide range of choices. The operationaldesign requirement for the material selected is that they be sufficientas judged by one skilled in the art to be used in the construction of amattress or article of upholstered furniture.

Many of the specific detailed element descriptions provided for in FIG.2 are also present in subsequent drawings. In the interest avoidingredundancy only those particular elements that substantially differ fromor are not included in FIG. 2 will be explicitly identified in thefollowing embodiments and corresponding drawings.

FIG. 3 illustrates a mattress assembly 300 according to an embodiment ofthe present disclosure that may include a single element mattress coreassembly 310 encased by a nested, zipperless ticking assembly 330.Nested, zipperless ticking assembly 330 may include a lower or basemattress ticking assembly 340 and an upper mattress ticking assembly360.

The ticking assembly is defined as being nested according to the presentdisclosure in that upper mattress ticking assembly 360 overlaps lower orbase mattress ticking assembly 340 in one or more of the vertical planarfaces (the mattress “border”) of the mattress construction. For purposesof the embodiment depicted in FIG. 3, the overlap is shown as beingpresent along and across the entire height of the mattress border,however an overlap of at least 1 inch in the mattress border iscontemplated by the disclosure. The nested nature of the presentdisclosure may also be satisfied if lower or base mattress tickingassembly 340 were disposed to the outside upper mattress tickingassembly 360.

The single element mattress core assembly 310 may in its simplest formbe a homogenous block of polyurethane foam. The single element mattresscore assembly 310 may also be made of any variety of resilientcushioning materials customarily used in the construction of mattressesor upholstered furnishings.

As with FIG. 2, the exemplary single element mattress core assembly 310depicted in FIG. 3 may also be an assembled composite of a plurality ofdifferent cushioning elements that are glued, laminated or attachedtogether to form a single unit. Utilizing different cushioningcompositions or identical cushioning compositions with varied density orIFD can yield differential feel on each panel oriented face of the coreassembly element.

Further referring to FIG. 3, the lower or base mattress ticking assembly340 covers the entirety of the bottom horizontal planar face (also knownto those skilled in the art as the bottom panel) of the mattress andcovers the four vertical planar faces (also known as the side borders)of the mattress. However in this embodiment depicted in FIG. 3, thematerials of lower or base mattress ticking assembly 340 may transitbeyond the right angle transition from the side border faces of mattresscore assembly 310 so that a portion 348 extends along a top horizontalplanar face of the mattress core assembly 310 and may cover a portion ofthe top-most horizontal planar face adjacent the side borders oradjacent the peripherally-extending sides of mattress core assembly 310.Portion 348 may have a peripheral edge that is disposed generally inwardof the peripherally-extending side and along a top side of mattress coreassembly 310.

The design of upper mattress ticking assembly 360 is fashioned so as tohave a portion 368 of the material extend into the area at the bottompanel from at least one of the four vertical sides of the mattressassembly. A preferred embodiment may have upper mattress tickingassembly 360 material extend from all four border faces to the bottompanel of the mattress, but this is not required. This feature permitsthe weight of the mattress and those sleeping or disposed upon themattress to assist in holding upper mattress ticking assembly 360 inplace.

In the embodiments shown in both FIGS. 2 and 3, the single elementmattress core assembly may also incorporate a traditional mattressinnerspring unit, without or without border rods, or pocketed coils orcombinations thereof, and said innerspring may be cushioned only on thetop and bottom horizontal planar faces of the innerspring unit oralternatively encased in foam or other flexible, resilient cushioningmaterials. Other internal support mechanisms customarily utilized in theproduction of mattresses and articles of upholstered furniture are alsoanticipated as being able to be encased by the nested, zipperlessticking assemblies of the present disclosure. This use of a broadvariety of materials to make the core assembly is fully anticipated forall potential embodiments according to the present disclosure.

FIG. 4 depicts a mattress assembly 400 according to an embodiment of thepresent disclosure that may include a two-piece mattress core assembly410 encased by a nested, zipperless ticking assembly 430. Nested,zipperless ticking assembly 430 may include a lower or base mattressticking assembly 440 and an upper mattress ticking assembly 460.Two-piece mattress core assembly 410 may include a lower mattress coreassembly 401 and an upper mattress core assembly 403 partially encasedby lower or base mattress ticking assembly 440 and an upper mattressticking assembly 460.

The ticking assembly is defined as being nested according to the presentdisclosure in that the upper mattress ticking assembly 460 overlaps thelower or base mattress ticking assembly 440 in one or more of thevertical planar faces (the mattress “border”) of the mattressconstruction. For purposes of the embodiment depicted in FIG. 4, theoverlap is shown as being present in the entire height of the mattressborder, however an overlap of at least 1 inch in the mattress border iscontemplated by the disclosure. The nested nature of the presentdisclosure is also be satisfied if the lower or base ticking assembly440 were disposed to the outside the upper mattress ticking assembly460.

As with FIG. 1 and FIG. 2, the exemplary lower mattress core assembly401 and upper mattress core assembly 403 depicted in FIG. 4 may also bean assembled composite of a plurality of different cushioning elementsthat are glued, laminated or attached together to form a single unit.Utilizing different cushioning compositions or identical cushioningcompositions with varied density or IFD can yield differential feel oneach panel oriented face of the core assembly element.

It is contemplated that both the lower mattress core assembly 401 and anupper mattress core assembly 403 are separate and not attached to oneanother and are able to rotated, flipped and interchanged individuallyfrom one another or in concert with one another, providing the end user,consumer with the flexibility to alter the cushioning attributes of themattress by removing the ticking assembly elements and reorienting thecore assembly elements. A two part core with each core possessing twodistinct sides could yield eight possible orientation combinations forthe mattress.

FIG. 4, similar to FIG. 1, depicts the lower or base mattress tickingassembly 440 and an upper mattress ticking assembly 460, where the loweror base mattress ticking assembly extends up the side borders only ofthe mattress and does not transit to the top panel face of the mattressassembly therefore not covering any portion of the upper mattress coreassembly 403.

The design of the upper mattress ticking assembly 460 is fashioned so asto have a portion 468 of the material extend into the area along thebottom panel of lower mattress core assembly 401 from at least one ofthe four vertical sides of the mattress assembly. The preferredembodiment would be to have the upper mattress ticking assembly 460material extend from all four border faces to the bottom panel of themattress, but this is not required. This feature permits the weight ofthe mattress and those sleeping or disposed upon the mattress to assistin holding the upper mattress ticking assembly 460 in place.

FIG. 5 illustrates a mattress assembly 500 according to an embodiment ofthe present disclosure that may include a two-piece mattress coreassembly 510 having a lower mattress core assembly 501 and an uppermattress core assembly 503 partially encased by a nested, zipperlessticking assembly 530 having a lower or base mattress ticking assembly540 and an upper mattress ticking assembly 560.

The ticking assembly is defined as being nested according to the presentdisclosure in that the upper mattress ticking assembly 560 overlaps thelower or base mattress ticking assembly 540 in one or more of thevertical planar faces (the mattress “border”) of the mattressconstruction. For purposes of the embodiment depicted in FIG. 54, theoverlap is shown as being present in the entire height of the mattressborder, however an overlap of at least 1 inch in the mattress border iscontemplated by the present disclosure. The nested nature of the presentdisclosure would also be satisfied if the lower or base mattress tickingassembly 540 were disposed to the outside the upper mattress tickingassembly 560.

Similar to FIG. 3, FIG. 5 depicts the lower or base mattress tickingassembly 540 that covers the entirety of the bottom horizontal planarface (also known to those skilled in the art as the bottom panel) of themattress and covers the four vertical planar faces (also known as theside borders) of the mattress. However in this embodiment depicted inFIG. 5, a portion 548 of the lower or base mattress ticking assembly 540may transit beyond the right angle transition from the side border facesof the mattress core assembly to the top horizontal planar face of theupper core assembly 503 as indicated and cover a portion of the top-mosthorizontal planar face of the upper mattress core assembly 510.

As with FIG. 2 and FIG. 3, the exemplary lower mattress core assembly501 and upper mattress core assembly 503 depicted in FIG. 4 may also bean assembled composite of a plurality of different cushioning elementsthat are glued, laminated or attached together to form a single unit.Utilizing different cushioning compositions or identical cushioningcompositions with varied density or IFD can yield differential feel oneach panel oriented face of the core assembly element.

The design of the upper mattress ticking assembly 560 is fashioned so asto have a portion 568 of the material extend into the area along thebottom of lower mattress core assembly 501 from at least one of the fourvertical sides of the lower mattress assembly 501. The preferredembodiment may be to have the upper mattress ticking assembly 560material extend from all four border faces to the bottom panel of themattress, but this is not required. This feature permits the weight ofthe mattress and those sleeping or disposed upon the mattress to assistin holding the upper mattress ticking assembly 560 in place.

It is contemplated that both the lower mattress core assembly 501 and anupper mattress core assembly 503 are separate and not attached to oneanother and are able to rotated, flipped and interchanged individuallyfrom one another or in concert with one another, providing the end user,consumer with the flexibility to alter the cushioning attributes of themattress by removing the ticking assembly elements and reorienting thecore assembly elements. A two part core with each core possessing twodistinct sides could yield eight possible orientation combinations forthe mattress.

In both FIGS. 4 and 5, either the lower or upper mattress core assemblyor both assemblies may also incorporate an innerspring unit, saidinnerspring cushioned only on the top and bottom horizontal planar facesof the innerspring unit or alternatively encased in foam or otherflexible, resilient cushioning materials. Other internal supportmechanisms customarily utilized in the production of mattresses andarticles of upholstered furniture are also anticipated as being able tobe encased by the present disclosure.

FIG. 6 illustrates a mattress assembly 600 according to an embodiment ofthe present disclosure that may include a three-piece mattress coreassembly 610 having a lower mattress core assembly 601, a middlemattress core assembly 602, and an upper mattress core assembly 603partially encased by a nested, zipperless ticking assembly 630 having alower or base mattress ticking assembly 640 and an upper mattressticking assembly 660.

As with previously recited embodiments, the ticking assembly may bedefined as being nested according to the present disclosure in thatupper mattress ticking assembly 660 overlaps the lower or base mattressticking assembly 640 in one or more of the vertical planar faces (themattress “border”) of the mattress construction. For purposes of theembodiment depicted in FIG. 6, the overlap is shown as being present inthe entire height of the mattress border; however an overlap of at least1 inch in the mattress border would be contemplated by the disclosure.The nested nature of the present disclosure would also be satisfied ifthe lower or base mattress ticking assembly 640 were disposed to theoutside the upper mattress ticking assembly 660.

The exemplary lower mattress core assembly 601, middle mattress coreassembly 602 and the upper mattress core assembly 603 depicted in FIG. 6may also be an assembled composite of a plurality of differentcushioning elements that are glued, laminated or attached together toform a single unit. Utilizing different cushioning compositions oridentical cushioning compositions with varied density or IFD can yielddifferential feel on each panel oriented face of the core assemblyelement.

It is contemplated that both the lower mattress core assembly 601,middle mattress core assembly 602, and upper mattress core assembly 603are separate and not attached to one another and are able to rotated,flipped and interchanged individually from one another or in concertwith one another, providing the end user, consumer with the flexibilityto alter the cushioning attributes of the mattress by removing theticking assembly elements and reorienting the core assembly elements. Athree part mattress core assembly approach with each core possessing twodistinct sides could yield more than thirty-two possible orientationcombinations for the mattress.

FIG. 6, similar to FIG. 2 and FIG. 4, depicts lower or base mattressticking assembly 640 and an upper mattress ticking assembly 660, wherelower or base mattress ticking assembly 640 extends up the side bordersonly of the mattress and does not transit along a top panel face ofmattress assembly 610 therefore not covering any portion of the uppermattress core assembly 603. In this FIG. 6, lower or base mattressticking assembly 640 is not depicted as extending against the verticalborder side of upper mattress core assembly 603. This embodiment is anexample where an originally manufactured mattress with only two coreassemblies may be enhanced by the end-user, consumer with the additionof an upper mattress core assembly 603 on an “after-market” basis atopthe original two core elements 601 and 603.

The selection of material for either or both of lower or base mattressticking assembly 640 and upper mattress ticking assembly 660 of thisembodiment or of other embodiments contained herein may be made withconsideration for providing sufficient structural lateral rigidity tohold unattached internal mattress core assemblies in place duringshipment and consumer use.

The design of the upper mattress ticking assembly 640 is fashioned so asto have a portion 668 of the material extend into the area at the bottomfrom at least one of the four vertical sides of mattress assembly 610.The preferred embodiment may have upper mattress ticking assembly 660material extend from all four border faces to the bottom panel of themattress, but this is not required. This feature permits the weight ofthe mattress and those sleeping or disposed upon the mattress to assistin holding the upper mattress ticking assembly 660 in place.

FIG. 7 illustrates a mattress assembly 700 according to an embodiment ofthe present disclosure that may include a three-piece mattress coreassembly 710 having a lower mattress core assembly 701, a middlemattress core assembly 702, and an upper mattress core assembly 703partially encased by a nested, zipperless ticking assembly 730 having alower or base mattress ticking assembly 740 and an upper mattressticking assembly 760.

As with previously recited embodiments, the ticking assembly is definedas being nested according to the present disclosure in that uppermattress ticking assembly 760 overlaps lower or base mattress tickingassembly 740 in one or more of the vertical planar faces (the mattress“border”) of the mattress construction. For purposes of the embodimentdepicted in FIG. 7, the overlap is shown as being present in the entireheight of the mattress border; however an overlap of at least 1 inch inthe mattress border is contemplated by the disclosure. The nested natureof the present disclosure may also be satisfied if lower or basemattress ticking assembly 740 were disposed to the outside uppermattress ticking assembly 760.

The exemplary lower mattress core assembly 701, middle mattress coreassembly 702, and upper mattress core assembly 703 depicted in FIG. 7may also be an assembled composite of a plurality of differentcushioning elements that are glued, laminated or attached together toform a single unit. Utilizing different cushioning compositions oridentical cushioning compositions with varied density or IFD can yielddifferential feel on each panel oriented face of the core assemblyelement.

It is contemplated that both lower mattress core assembly 701, middlemattress core assembly 702, and upper mattress core assembly 703 areseparate and not attached to one another and are able to rotated,flipped and interchanged individually from one another or in concertwith one another, providing the end user, consumer with the flexibilityto alter the cushioning attributes of the mattress by removing theticking assembly elements and reorienting the core assembly elements. Athree part mattress core assembly approach with each core possessing twodistinct sides could yield more than thirty-two possible orientationcombinations for the mattress.

FIG. 7, similar to FIG. 3 and FIG. 5, depicts lower or base mattressticking assembly 740 and upper mattress ticking assembly 760, where thelower or base mattress ticking assembly extends up the side borders ofthe mattress core assembly and a portion 748 does transit to the toppanel face of the mattress assembly covering a portion of upper mattresscore assembly 703.

The selection of material for either or both of lower or base mattressticking assembly 740 and upper mattress ticking assembly 760 of thisembodiment or of other embodiments contained herein may be made withconsideration for providing sufficient structural lateral rigidity tohold unattached internal mattress core assemblies in place duringshipment and consumer use.

The design of the upper mattress ticking assembly 760 is fashioned so asto have a portion 768 of the material extend into the area at the bottomfrom at least one of the four vertical sides of the mattress assembly.The preferred embodiment may have upper mattress ticking assembly 760material extend from all four border faces to the bottom panel of themattress, but this is not required. This feature permits the weight ofthe mattress and those sleeping or disposed upon the mattress to assistin holding upper mattress ticking assembly 760 in place.

FIG. 8 illustrates a mattress assembly 800 according to an embodiment ofthe present disclosure that may include a three-piece mattress coreassembly 810 having a lower mattress core assembly 801, a middlemattress core assembly 802, and an upper mattress core assembly 803partially encased by a nested, zipperless ticking assembly 830 having alower or base mattress ticking assembly 840 and an upper mattressticking assembly 860.

As with previously described embodiments, the ticking assembly isdefined as being nested according to the present disclosure in thatupper mattress ticking assembly 860 overlaps lower or base mattressticking assembly 840 in one or more of the vertical planar faces (themattress “border”) of the mattress construction. For purposes of theembodiment depicted in FIG. 8, the overlap is shown as being present inthe entire height of the mattress border; however an overlap of at least1 inch in the mattress border is contemplated by the present disclosure.The nested nature of the present disclosure would also be satisfied iflower or base mattress ticking assembly 840 were disposed to the outsideupper mattress ticking assembly 860.

The exemplary lower mattress core assembly 801, middle mattress coreassembly 802, and upper mattress core assembly 80 depicted in FIG. 8 mayalso be an assembled composite of a plurality of different cushioningelements that are glued, laminated or attached together to form a singleunit. Utilizing different cushioning compositions or identicalcushioning compositions with varied density or IFD can yielddifferential feel on each panel oriented face of the core assemblyelement.

It is contemplated that both lower mattress core assembly 801, middlemattress core assembly 802, and upper mattress core assembly 803 areseparate and not attached to one another and are able to rotated,flipped and interchanged individually from one another or in concertwith one another, providing the end user, consumer with the flexibilityto alter the cushioning attributes of the mattress by removing theticking assembly elements and reorienting the core assembly elements. Athree part mattress core assembly approach with each core possessing twodistinct sides could yield more than thirty-two possible orientationcombinations for the mattress.

FIG. 8, similar to FIG. 3 and FIG. 5, depicts lower or base mattressticking assembly 840 and upper mattress ticking assembly 860, where thelower or base mattress ticking assembly extends up the side borders ofthe mattress; however, in this FIG. 8, lower or base mattress tickingassembly 840 is not depicted as extending against the vertical borderside of upper mattress core assembly 803, rather lower or base mattressticking assembly 840 extends against the vertical border side of lowermattress core assembly 801 and middle mattress core assembly 802 onlyand then a portion 848 transits in partially atop an upper horizontalplanar face of middle mattress core assembly 802, effectively restingand sandwiched partially between middle mattress core assembly 802 andupper mattress core assembly 803. This embodiment is an example where anoriginally manufactured mattress conforms to the design depicted inFIGS. 4 and 5, and the two core assemblies may be enhanced by theend-user, consumer with the addition of a third core assembly, hererepresented by upper mattress core assembly 803, on an “after-market”basis atop the original two core elements 801 and 802.

The selection of material for either or both of the lower or basemattress ticking assembly 840 and an upper mattress ticking assembly 860of this embodiment or of other embodiments contained herein may be madewith consideration for providing sufficient structural lateral rigidityto hold unattached internal mattress core assemblies in place duringshipment and consumer use.

The design of the upper mattress ticking assembly 860 is fashioned so asto have a portion 868 of the material extend into the area along abottom of the lower mattress core assembly 801 from at least one of thefour vertical sides of the mattress assembly. The preferred embodimentwould be to have the upper mattress ticking assembly 860 material extendfrom all four border faces to the bottom panel of the mattress, but thisis not required. This feature permits the weight of the mattress andthose sleeping or disposed upon the mattress to assist in holding theupper mattress ticking assembly 860 in place.

FIG. 9 is a perspective view of a lower or base mattress tickingassembly 940 according to the present disclosure for use in a nested,zipperless mattress ticking assembly or features incorporable in thosepreviously depicted in FIGS. 2, 4, and 6, along with the core assemblyelements depicted previously.

As shown in FIG. 9, lower or base mattress ticking assembly 940 iscomprised of a textile that is fashioned into a shape appropriatelysized to contain the mattress core elements (not shown in FIG. 9 forclarity). It is contemplated by the present disclosure that lower orbase mattress ticking assembly 940 may be fashioned from one continuouspiece of fabric or alternatively from a plurality of separate fabricsthat sewn together, said separate fabrics may be similar or dissimilarin their compositions and their constructions.

Corners 945 of lower or base mattress ticking assembly 940 may be formedby folding the fabric or using sewn seams. Sewn seams 947 may optionallybe used to assemble disparate textile elements into a comprehensive,composite structure. The locations and orientations of the seams asdepicted are not intended to limiting are merely exemplary of oneapproach to fashion the lower or base mattress ticking assembly 940. Theplacement of sewn seams in all contemplated embodiments of the presentdisclosure may be used to facilitate the orderly placement and situationof the core assembly elements, provide structural support for andrestrict lateral movement of the core assembly elements as well offeraesthetically pleasing finished appearance of the entire mattress.

Lower or base mattress ticking assembly 940 may be constructed frommaterials that provide appropriate structural integrity to contain thecore elements without additional supporting design approaches or thetextiles may be fashioned to incorporate hems or elastic bands orfabrics possessing elastic properties. For example, a portion 949 oflower or base mattress ticking assembly 940 may incorporate hems orelastic bands or fabrics possessing elastic properties. Such portion 949may correspond to portions of the lower or base mattress tickingassemblies described above and be disposed along the vertical sides ofthe mattress core(s) to resiliently restrain the lower or base mattressticking assemblies in position on the mattress core(s). Portion 949 maybe a woven or knitted fabric having an elastic polyurethane materialsuch as a LYCRA elastic polyurethane material.

FIG. 10 is a perspective view of a lower or base mattress tickingassembly 1040 according to the present disclosure for use in a nested,zipperless mattress ticking assembly or features incorporable in thosepreviously depicted in FIGS. 3, 5, and 7, along with the core assemblyelements depicted previously.

Lower or base mattress ticking assembly 1040 may include a textile thatis fashioned into a shape appropriately sized to contain the coreelements (not shown in FIG. 10 for clarity). It is contemplated by thepresent disclosure that lower or base mattress ticking assembly 1040 maybe fashioned from one continuous piece of fabric or alternatively from aplurality of separate fabrics that sewn together, said separate fabricsmay be similar or dissimilar in their compositions and theirconstructions.

The corners 1045 of lower or base mattress ticking assembly 1040 may beformed by folding the fabric or using sewn seams. Sewn seams 1047 mayoptionally be used to assemble disparate textile elements into acomprehensive, composite structure. The locations and orientations ofthe seams as depicted are not intended to limiting are merely exemplaryof one approach to fashion the lower or base mattress ticking assembly1040.

In this embodiment, lower or base mattress ticking assembly 1040 may beconstructed from materials that provide appropriate structural integrityto contain the core elements without additional supporting designapproaches or the textiles may be fashioned to incorporate hems orelastic bands or fabrics possessing elastic properties. For example, aportion 1041 of lower or base mattress ticking assembly 1040 mayincorporate hems or elastic bands or fabrics possessing elasticproperties. Such portion 1041 may correspond to portions of the lower orbase mattress ticking assemblies described above and may rest atop orextend along a top horizontal side of a mattress core as described aboveto resiliently restrain the lower or base mattress ticking assemblies inposition on the mattress core(s). Portion 1041 may be a woven or knittedfabric having an elastic polyurethane material such as a LYCRA elasticpolyurethane material.

Opening 1043 in the top of lower or base mattress ticking assembly 1040by this additional fabric structure 1041 may be sufficiently sized andconfigured to permit insertion of a mattress core assembly elements intothe cavity provided by lower or base mattress ticking assembly 1040. Theadditional fabric structure may be fashioned from a single continuouspiece of fabric or cloth and may also be formed by a plurality ofseparate and similar or dissimilar fabrics that are joined together withcustomary sewing techniques.

The opening created by the additional fabric structure 1041 asillustrated in FIG. 10 is rectangular, however it is anticipated thatalternate designs and geometries, such as ovals, circles, diamonds orellipses, might be fashioned and would fall within the design intent ofthe present disclosure.

FIG. 11 is a perspective view of an upper mattress ticking assembly 1160according to the present disclosure for use in a nested, zipperlessmattress ticking assembly or features incorporable in those previouslydescribed above, and employed with the core assembly elements previouslydescribed above.

Upper mattress ticking assembly 1160 may include a ticking fabric 1161is fashioned to accommodate the shape of a mattress core assembly.Ticking fabric 1161 may be formed from a single continuous piece oftextile material or from a plurality of separate and either similar ordissimilar textile materials. In some embodiments, ticking fabric 1161may include a plurality of fabric layers. In some embodiments, tickingfabric 1161 may include a quilted plurality of fabric layers.

Upper mattress ticking assembly 1160 may include a second fabric 1162,which may possess desirable elastomeric properties which may beattached, preferably by sewing, to the bottom oriented edge of tickingfabric 1161. This second fabric need not be elastomeric and may beselected from a non-elastomeric material and the construction techniquemay use elastomeric material to add elastomeric properties to thisportion of the design.

Seams may be sewn to add definition to the shape of the material andthis embodiment, such as seams depicted at the vertical corners 1165disposed over a mattress 1110 and a horizontal transition point 1167disposed over vertical border faces of mattress 1110 to an upperhorizontal planar (panel) face (not shown in FIG. 11) of mattress 1110.

FIG. 12 is a perspective view of an underside of an upper mattressticking assembly 1260 according to the present disclosure for use in anested, zipperless mattress ticking assembly or features incorporable inthose previously described above, and employed with the core assemblyelements previously described above.

In this illustrated embodiment, upper mattress ticking assembly 1260 mayinclude a ticking fabric 1261 and a second fabric 1263 fashioned toaccommodate a shape of a mattress core assembly (not shown in FIG. 12).Ticking fabric 1261 may be formed from a single continuous piece oftextile material or from a plurality of separate and either similar ordissimilar textile materials.

Second fabric 1263, which may possess desirable elastomeric propertiesand may be attached, preferably by sewing, to the bottom oriented edgeof ticking fabric 1261. This second fabric need not be elastomeric andmay be selected from a non-elastomeric material and the constructiontechnique may use elastomeric material to add elastomeric properties tothis portion of the design.

Seams may be sewn to add definition to the shape of the material andthis embodiment, such seams are depicted at the vertical corners ofupper mattress ticking assembly 1260.

The second fabric 1263 may, in a preferred embodiment, be sufficientlysized so as to transit to some degree across the lower horizontal planarface of a mattress assembly (not shown in FIG. 12) in the area 1265indicated by the bottom portion of the second fabric 1263. Also in thisembodiment, an elastic band 1267 may be sewn into a hem of the bottomportion of the second fabric 1263. This embodiment as depicted leaves anopening 1269 sufficiently large enough to permit this upper tickingassembly to be stretched open to be installed over an assembly of amattress core or a plurality of mattress core assembly elements thathave been encased in a lower mattress ticking assembly.

FIG. 13 is a perspective view of an underside of an upper mattressticking assembly 1360 according to the present disclosure for use in anested, zipperless mattress ticking assembly or features incorporable inthose previously described above, and employed with the core assemblyelements previously described above.

In this illustrated embodiment, upper mattress ticking assembly 1360 mayinclude ticking fabric 1361 and a second fabric 1363, and may befashioned to accommodate a shape of a mattress core assembly (not shownin FIG. 13). For example, ticking fabric 1361 may be formed from asingle continuous piece of textile material or from a plurality ofseparate and either similar or dissimilar textile materials.

Second fabric 1363, which may possess desirable elastomeric propertiesis attached, preferably by sewing, to the bottom oriented edge ofticking fabric 1361. This second fabric need not be elastomeric and maybe selected from a non-elastomeric material and the constructiontechnique may use elastomeric material to add elastomeric properties tothis portion of the design.

Seams may be sewn to add definition to the shape of the material andthis embodiment, such seams are depicted at the vertical corners ofupper mattress ticking assembly 1360.

The second fabric 1363 may, in a preferred embodiment, sufficientlysized so as to transit to some degree across the lower horizontal planarface of a mattress assembly in an area indicated by the bottom portionof the second fabric 1363. Also in this embodiment, an elastic band 1367may be sewn into a hem of the bottom portion of second fabric 1363. Thisembodiment as depicted leaves an opening 1365 sufficiently large enoughto permit this upper mattress ticking assembly to be stretched open tobe installed over an mattress assembly of one or a plurality of mattresscore assembly elements that have been encased in a lower tickingassembly. The noted difference between this FIG. 13 and the previousFIG. 12 is the anticipation that the opening 1365 may be shaped in anyshape that nonetheless permits this upper ticking assembly to bestretched open to be installed over an assembly of the plurality ofmattress core assembly elements that have been encased in a lowerticking assembly.

FIG. 14 illustrates a mattress assembly 1400 taken along a head or afoot thereof according to an embodiment of the present disclosure thatmay include a plurality of separate upper mattress core assemblies 1411and 1413 atop a single lower mattress core assembly 1415, said coreassemblies encased by a nested, zipperless ticking assembly 1430.Nested, zipperless ticking assembly 1430 may include a lower or basemattress ticking assembly 1440 and an upper mattress ticking assembly1460.

Lower mattress core assembly 1415 is disposed beneath first uppermattress core assembly 1411 and second upper mattress core assembly1415.

As with previously recited embodiments, the exemplary lower mattresscore assembly 11415 and first upper mattress core assembly 1411 andsecond upper mattress core assembly 1413 may be each, more than one orall an assembled composite of a plurality of different cushioningelements that are glued, laminated or attached together to form a singleunit. Utilizing different cushioning compositions or identicalcushioning compositions with varied density or IFD can yielddifferential feel on each panel oriented face of the core assemblyelement.

It is contemplated that lower mattress core assembly 1415 and firstupper mattress core assembly 1411 and second upper mattress coreassembly 1413 are separate and not attached to one another and are ableto rotated, flipped and interchanged individually from one another or inconcert with one another, providing the end user, consumer with theflexibility to alter the cushioning attributes of the mattress byremoving the ticking assembly elements and reorienting the core assemblyelements. A multi part core with each core possessing two distinct sidescould yield at least 12 possible orientation combinations for themattress.

This “split-top” design could permit mattress manufacturers to markettheir mattress as being suitable for two or more sleepers who use themattress yet desire differential feel or comfort profiles for the sideof the mattress upon which they intend to sleep. While it may be mostsuitable for larger sized mattress, such as queens and kings, theapplicability of this design variation is anticipated for all sizes ofmattress.

This “split-top” design configuration would be fully or partiallyencased by the present disclosure consisting of upper mattress tickingassembly 1460 and lower mattress ticking assembly 1440. This embodimentis further depicted to show the area at the bottom panel 1468 where theupper mattress ticking assembly 1460 extends below the bottom panel fromat least one of the four vertical sides of the mattress assembly. Thepreferred embodiment would be to have the upper mattress tickingassembly 1460 material extend from all four border faces to the bottompanel of the mattress, but this is not required. This feature permitsthe weight of the mattress and those sleeping or disposed upon themattress to assist in holding the upper mattress ticking assembly 1460in place.

FIG. 15 illustrates a mattress assembly 1500 taken along a head or afoot thereof according to an embodiment of the present disclosure thatmay include a single upper mattress core assembly 1515 atop a pluralityof separate lower mattress core assemblies 1516 and 1517, said coreassemblies encased by a nested, zipperless ticking assembly 1530.Nested, zipperless ticking assembly 1530 may include a lower or basemattress ticking assembly 1540 and an upper mattress ticking assembly1560.

First lower mattress core assembly 1516 and second lower mattress coreassembly 1517 are disposed beneath upper mattress core assembly 1515.

As with previously recited embodiments, the exemplary first lowermattress core 1516 and second lower mattress core assembly 1517 that aredisposed beneath upper mattress core assembly 1515 may be each, morethan one or all an assembled composite of a plurality of differentcushioning elements that are glued, laminated or attached together toform a single unit. Utilizing different cushioning compositions oridentical cushioning compositions with varied density or IFD can yielddifferential feel on each panel oriented face of the core assemblyelement.

It is contemplated that first lower mattress core assembly 1516 andsecond lower mattress core assembly 1517 are disposed beneath uppermattress core assembly 1515 are separate and not attached to one anotherand are able to rotated, flipped and interchanged individually from oneanother or in concert with one another, providing the end user, consumerwith the flexibility to alter the cushioning attributes of the mattressby removing the ticking assembly elements and reorienting the coreassembly elements. A multi part core with each core possessing twodistinct sides could yield at least 12 possible orientation combinationsfor the mattress.

This “split-bottom” design could permit mattress manufacturers to markettheir mattress as being suitable for two or more sleepers who use themattress yet desire differential feel or comfort profiles for the sideof the mattress upon which they intend to sleep. While it may be mostsuitable for larger sized mattress, such as queens and kings, theapplicability of this design variation is anticipated for all sizes ofmattress.

This “split-bottom” design configuration may be fully or partiallyencased by the present disclosure of upper mattress ticking assembly1560 and the lower mattress ticking assembly 1540. This embodiment isfurther depicted to show the area at the bottom panel 1568 where uppermattress ticking assembly 1560 extends below the bottom panel from atleast one of the four vertical sides of the mattress assembly. Thepreferred embodiment may have upper mattress ticking assembly 1560material extend from all four border faces to the bottom panel of themattress, but this is not required. This feature permits the weight ofthe mattress and those sleeping or disposed upon the mattress to assistin holding the upper mattress ticking assembly 1560 in place.

FIG. 16 illustrates a mattress assembly 1600 taken along a head or afoot thereof according to an embodiment of the present disclosure thatmay include a plurality of upper mattress core assemblies 1611 and 1613atop a plurality of separate lower mattress core assemblies 1616 and1617, said core assemblies encased by a nested, zipperless tickingassembly 1630. Nested, zipperless ticking assembly 1630 may include alower or base mattress ticking assembly 1640 and an upper mattressticking assembly 1660.

First lower mattress core assembly 1616 and second lower mattress coreassembly 1617 are disposed beneath first upper mattress core assembly1611 and second upper mattress core assembly 1613.

As with previously recited embodiments, the exemplary first lowermattress core 1616 and first upper mattress core assembly 1611, andsecond lower mattress core assembly 1617 and second upper mattress coreassembly 1613 that may be each, more than one or all an assembledcomposite of a plurality of different cushioning elements that areglued, laminated or attached together to form a single unit. Utilizingdifferent cushioning compositions or identical cushioning compositionswith varied density or IFD can yield differential feel on each paneloriented face of the core assembly element.

It is contemplated that first lower mattress core assembly 1616 andsecond lower mattress core assembly 1617 that are disposed beneath firstupper mattress core assembly 1611 and a second upper mattress coreassembly 1613 are separate and not attached to one another and are ableto rotated, flipped and interchanged individually from one another or inconcert with one another, providing the end user, consumer with theflexibility to alter the cushioning attributes of the mattress byremoving the ticking assembly elements and reorienting the core assemblyelements. A multi part core with each core possessing two distinct sidescould yield at least 12 possible orientation combinations for themattress.

This “split-top and split-bottom” design could permit mattressmanufacturers to market their mattress as being suitable for two or moresleepers who use the mattress yet desire differential feel or comfortprofiles for the side of the mattress upon which they intend to sleep.While it may be most suitable for larger sized mattress, such as queensand kings, the applicability of this design variation is anticipated forall sizes of mattress.

This “split-top and split-bottom” design configuration would be fully orpartially encased by the present disclosure of upper mattress tickingassembly 1660 and lower mattress ticking assembly 1640. This embodimentis further depicted to show the area at the bottom panel 1668 where theupper mattress ticking assembly 1660 extends below the bottom panel fromat least one of the four vertical sides of the mattress assembly. Thepreferred embodiment would be to have upper mattress ticking assembly1660 material extend from all four border faces to the bottom panel ofthe mattress, but this is not required. This feature permits the weightof the mattress and those sleeping or disposed upon the mattress toassist in holding the upper mattress ticking assembly 1600 in place.

The enhanced modularity of the design advanced in FIGS. 13, 14 and 15may also result in logistical costs savings as the smaller pieces thatare used to construct a larger mattress may be packaged separately fromone another, thereby resulting in shipping costs savings as a result ofthe certain punitive shipping charge premiums that are typicallyassessed to large, oversized or non-standard parcels that may be avoidedby elements of the present disclosure.

It is also fully anticipated by the present disclosure that theinteriorly disposed mattress core elements that are depicted herein maybe encased in knitted, tubular fire barrier socks or sleeves or that ifnot so covered or encased, be built into mattresses that utilizeintegrated fire barrier textile systems to impart into the mattress theability to satisfy the full-scale fire test requirements of 16 CFR 1633.The absence of this feature in many of the figures herein is a result ofthe desire to depict the present disclosure and various embodiments ofthe present disclosure as clearly as is feasible.

FIG. 17 illustrates a portion of a top side 1762 of an upper mattressticking assembly 1760 according to an embodiment of the presentdisclosure extendable over a top side of a mattress core assembly. Inthis illustrated embodiment, top side 1762 of an upper mattress tickingassembly 1760 may include a single ticking layer 1763 such as a singlelayer.

FIG. 18 illustrates a portion of a top side 1862 of an upper mattressticking assembly 1860 according to an embodiment of the presentdisclosure extendable over a top side of a mattress core assembly. Inthis illustrated embodiment, top side 1862 of an upper mattress tickingassembly 1860 may include a plurality of ticking layers 1863 and 1865each of which may be single layer, which layer are not attached togetheralong the top side.

FIG. 19 illustrates a portion of a top side 1962 of an upper mattressticking assembly 1960 according to an embodiment of the presentdisclosure extendable over a top side of a mattress core assembly. Inthis illustrated embodiment, top side 1962 of an upper mattress tickingassembly 1960 may include a plurality of ticking layers 1963 and 1965,each of which may be single layer or a plurality of layers, which layersmay be physically attached or connected together along the top side. Forexample, the layers may be physically attached or connected together bysewing or stitching with thread 1961.

FIG. 20 illustrates a portion of a top side 1262 of an upper mattressticking assembly 2060 according to an embodiment of the presentdisclosure extendable over a top side of a mattress core assembly. Inthis illustrated embodiment, top side 2062 of an upper mattress tickingassembly 2060 may include a plurality of ticking layers 2063, 2064, and2065, each of which may be single layer or a plurality of layers, whichlayers may be physically attached or connected together along the topside. For example, layer 2063 may be a top fabric or quilt top layer,layer 2064 may be a batting or insulating material, and layer 2065 maybe a backing material. The layers may be physically attached orconnected together by sewing or stitching with thread 2061.

The upper mattress ticking assemblies disclosed in connection with FIGS.17-20 may include any of the materials disclosed herein and may beemployed in any of the disclosed mattress assembly embodiments. Thebottom side of lower mattress ticking assembly may be similarlyconfigured as described in connection with the upper mattress tickingassemblies.

FIG. 21 illustrates a portion of a nested, zipperless mattress tickingassembly 2130 according to an embodiment of the present disclosure withportions of an upper mattress ticking assembly 2160 and a lower mattressticking assembly 2140 being physically attachable or connectable via aplurality of buttons or snaps 2170. For example, buttons or snaps 2170may operably connect a portion 2168 of upper mattress ticking assembly2160 that extends over a bottom side 2144 of lower mattress tickingassembly 2140. The plurality of buttons or snaps 2170 may be disposed inone or more corners, along one or more sides, along head, and/or alongthe foot of the mattress assembly. In other embodiments, a plurality ofbuttons or snaps may be disposed along a portion of the vertical sidesof the nested, zipperless mattress ticking assembly. In someembodiments, the upper and lower mattress ticking assemblies may beattached along and adjacent one of the sides of the mattress assembly,which would allow removal and replacement of the nested, zipperlessmattress ticking assembly.

FIG. 22 illustrates a portion of a nested, zipperless mattress tickingassembly 2230 according to an embodiment of the present disclosure withportions of an upper mattress ticking assembly 2260 and a lower mattressticking assembly 2240 being physically attachable or connectable viabeing sewn or stitched together with thread 2272. For example, one ormore stitches may be operably connect a portion 2268 of upper mattressticking assembly 2260 that extends over a bottom side 2244 of lowermattress ticking assembly 2240. The one or more stitches may be disposedin one or more corners, along one or more sides, along head, and/oralong the foot of the mattress assembly. In other embodiments, astitches may be disposed a portion of the vertical sides of the nested,zipperless mattress ticking assembly. In some embodiments, the upper andlower mattress ticking assemblies may be stitched together along andadjacent one of the sides of the mattress assembly, which would allowremoval and replacement of the nested, zipperless mattress tickingassembly. In other embodiments, portions an upper mattress tickingassembly and a lower mattress ticking assembly may be stitched along theentire sides of the mattress core assembly, for example where an uppermattress ticking assembly has an opening allowing receipt of a mattresscore assembly.

FIG. 23 illustrates a portion of a nested, zipperless mattress tickingassembly 2330 according to an embodiment of the present disclosure withportions of an upper mattress ticking assembly 2360 and a lower mattressticking assembly 2340 being physically attachable or connectable via oneor more hook-and-loop fasteners 2373. For example, a hoop portion 2374and a loop portion 2375 may operably connect a portion 2368 of uppermattress ticking assembly 2360 that extends over a bottom side 2344 oflower mattress ticking assembly 2340. The one or more hook-and-loopfasteners 2473 may be disposed in one or more corners, along one or moresides, along head, and/or along the foot of the mattress assembly. Inother embodiments, one or more hook-and-loop fasteners may be disposedalong a portion of the vertical sides of the nested, zipperless mattressticking assembly. In some embodiments, the upper and lower mattressticking assemblies may be attached along and adjacent one of the sidesof the mattress assembly, which would allow removal and replacement ofthe nested, zipperless mattress ticking assembly.

From the present disclosure, it will be appreciated that the variousembodiments of the mattress assemblies may include only an uppermattress ticking assembly disposed over a mattress core assembly.

The various embodiments of the mattress assembly may be configured tomeet the flammability standards of the 16 CFR 1633. For example, thenested, zipperless mattress ticking assembly alone may provide flameresistant properties necessary for the mattress assembly to meet theflammability standards of the 16 CFR 1633. In other embodiments, themattress assembly may include one or more fire barrier interlinerscovering said mattress core assembly to provide flame resistantproperties necessary for the mattress assembly to meet the flammabilitystandards of the 16 CFR 1633. In still other embodiments, the mattresscore assembly may include one or more fire barrier interliners coveringsaid mattress core assembly and the nested, zipperless mattress tickingassembly in combination together are operable to provide flame resistantproperties necessary for the mattress assembly to meet the flammabilitystandards of the 16 CFR 1633, i.e. neither the nested, zipperlessmattress ticking assembly nor the mattress assembly along beingsufficient but together the flammability standards of the 16 CFR 1633.

FIG. 24 illustrates a mattress core assembly 2400 taken along a head ora foot thereof according to an embodiment of the present disclosure thatmay include a plurality of layers of resilient cushioning or fillingmaterials 2411, 2412, and 2413, said materials encased in a textile sockor sleeve 2450. FIG. 24 utilizes a scheme of changing flexible foam IFDvalues to promote the comfort of the end user, consumer.

In FIG. 24, the mattress core assembly 2410 includes upper layer 2411,middle layer 2412, and bottom layer 2413. All three layers in thisdepiction may be laminated together with adhesive material so as toconstitute a singular composite piece core assembly, and this compositepiece may be encased in textile sock or sleeve 2450.

The textile sock or sleeve 2450 in this preferred embodiment may includeflame retardant or resistant materials customarily identified as a firebarrier interliner 2450, however the textile used may also be selectedfrom a non-flame retardant or non-flame resistant material so as to makethe mattress core assembly easier to handle during manufacture orconsumer, end-user utilization. Mattress core assembly 2400 may employedas a single mattress core in a mattress assembly having a nested,zipperless mattress ticking assembly according to embodiments of thepresent disclosure or a plurality of mattress core assemblies 240 may beincorporated in a mattress assembly having a nested, zipperless mattressticking assembly according to embodiments of the present disclosure.Textile sock or sleeve 2450 such as a fire barrier interliner 2450 of aplurality of fire barrier interliners may be incorporated into thevarious embodiments described above.

One possible iteration of the internal foam formulations depicted inthis FIG. 24 is a laminated foam structure comprising foam slabs layeredand attached to each other with adhesive material in the followingsequence: an upper layer 1610 of 1″ natural latex with an IFD of 14, amiddle layer 1620 of 1″ of latex with an IFD of 19 or higher and abottom layer 1630 of a 2″ gel visco with an IFD range of 10-16.

Alternative ordering, such as the selection of ascending values ofdensities and IFDs, descending values of densities and IFDs ornon-sequential ordering of densities and IFDs, is anticipated by thepresent disclosure.

As previously indicated, comfort is a highly subjective attribute onwhich the quality of mattresses may be judged by end-users, consumers.As many physical properties of a mattress or article of upholsteredfurniture may be altered or sequenced in particular orders to deliverdifferent comfort properties, it is important for the mattressmanufacturer to clearly and consistently orient the elements of themattress so as to faithfully replicate the feel experienced by aconsumer in the showroom. In the DTC selling model a benefit can be nowbe derived by mattress designs that permit consumers to reorient orresequence the interiorly disposed elements.

It is also fully anticipated by the present disclosure that theinteriorly disposed mattress core elements that are depicted herein maybe fully or partially encased in knitted, tubular fire barrier socks orsleeves or that if not so covered or encased, be built into mattressesthat utilize integrated fire barrier textile systems or other customaryfire barrier systems to impart into the mattress the ability to satisfythe full-scale fire test requirements of 16 CFR 1633. The absence ofthis feature in many of the FIGS. herein is a result of the desire todepict the present disclosure and various embodiments of the presentdisclosure as clearly as is feasible and not to indicate that a nested,zipperless mattress ticking assembly is able to satisfy regulatorydriven, full-scale mattress fire testing requirements without theinclusion of a fire barrier system.

Specific Embodiments

Two embodiments (one twin sized and one queen sized) of the presentdisclosure was prepared in the following manner:

A lower or base mattress ticking assembly was fashioned using a 5.5ounce per square woven cotton fabric. This material was sewn to create afive sided, flattened fabric rectangle box with bottom dimensions of 39″wide×75″ long for twin and 60″ wide×80″ long for queen. The four sidesof the box were prepared, also from the selected cotton material toextend 10″ high in the vertical direction. Seams were sewn at thecorners to provide structural definition. An alternative design was alsomade that utilized a knitted fabric with an integrally and unitarilyformed fire barrier fabric.

To the exposed top edge of the a knitted fabric comprised of nylon andlycra was sewn in accordance with the design depicted in FIG. 9 by 949

For the twin sized sample, two separate pieces of foam were covered in aknitted fire barrier fabric comprised of yarns formed from para-aramidfibers and totally chlorine free FR rayon yarns. One piece of foam wasselected to serve as the lower mattress core assembly and was selectedfrom polyurethane foam and was homogeneous in nature. This lowermattress core piece measured 38″ wide×74.5″ long by 6″ hall. The uppermattress core assembly was comprised of two separate pieces of foam, onelatex and one visco elastic foam infused with gel, each measuring 38″wide×74.5″ long×2″ high, which were glued together to form a one pieceupper mattress core assembly measuring 38″ wide×74.5″ long×4″ high priorto being encased in the knitted fire barrier.

The lower mattress core assembly and the composited upper mattress coreassembly were then inserted into the open cavity of the lower or basemattress ticking assembly in the appropriate order.

The assembled mattress core assemblies and lower or base mattressticking assembly were then ready to be covered by the upper mattressticking assembly.

The upper mattress ticking assembly was fashioned by using a knittednylon ticking with a unitarily and integrally formed fire barrierelement. This material was sewn to create a five sided, flattened fabricrectangle box with bottom dimensions of 39″ wide×75″ long for twin and60″ wide×80″ long for queen. The height of this box was tailored to be8″ and to the exposed edges of the box a 14″ wide band of nylon/lyrcaknitted fabric with elastomeric properties was sewn. The opening thatremained was then hemmed with an additional elastic band to mimic thecharacteristics of a fitted sheet.

The same sequences of steps and elements was followed for the queensized unit, except the dimensions of the queen are different, as wouldthe dimensions of the other sizes when those are constructed.Additionally, the preferred embodiments of the queen-sized andking-sized mattresses were built as depicted in FIG. 14 recited herein.

For the queen sized mattress, three separate pieces of foam were coveredin a knitted fire barrier fabric comprised of yarns formed frompara-aramid fibers and totally chlorine free FR rayon yarns. One pieceof foam was selected to serve as the lower mattress core assembly andwas selected from polyurethane foam and was homogeneous in nature. Thislower mattress core piece measured 60″ wide×80″ long by 6″ high. Theupper mattress core assembly was comprised of four separate pieces offoam, two latex and two visco elastic foam infused with gel, eachmeasuring 30″ wide×80″ long×2″ high. One piece of latex was glued to onepiece of visco elastic foam infused with gel to form an upper mattresscore assembly measuring 30″ wide×80″ long×4″ high. The four separatepieces yield two identical upper core assembly elements and each wasthen encased in the knitted fire barrier.

The lower mattress core assembly and the two composited upper mattresscore assemblies were then inserted into the open cavity of the lower orbase mattress ticking assembly in the appropriate order.

The assembled mattress core assemblies and lower or base mattressticking assembly were then ready to be covered by the upper mattressticking assembly.

The upper mattress ticking assembly was fashioned by using a knittednylon ticking with a unitarily and integrally formed fire barrierelement. This material was sewn to create a five sided, flattened fabricrectangle box with dimensions of 60″ wide×80″ long for queen. The heightof this box was tailored to be 8″ and to the exposed edges of the box a14″ wide band of nylon/lycra knitted fabric with elastomeric propertieswas sewn. The opening that remained was then hemmed with an additionalelastic band to mimic the characteristics of a fitted sheet.

The twin sized mattresses were subjected to full-scale fire testingunder 16 CFR 1632.4 and 16 CFR 1633 and were observed to pass therequirements of these tests. The queen sized mattress was used forassembly trials and shipping trials as well as side-by-side comparisonsof traditional, zipper-based closing processes versus the improved,faster closing process for the present disclosure and favorable resultswere also observed.

Throughout this description, in the interest of descriptive simplicity,only the term mattress has been used to describe the disclosure in termsof articles intended for sleeping upon. It is fully contemplated andanticipated the present disclosure is applicable to and offers benefitfor the construction of mattresses and the construction of mattressfoundations as defined herein. Any reference in the above specificationsto the term mattress is equally intended to be applicable to the designof mattress foundations as well.

The present disclosure relates to a ticking assembly, which includes theoutermost layer of fabric, fabrics and/or related material that enclosesa core and upholstery materials of a mattress or mattress pad. Amattress ticking or assembly of a mattress ticking and certaincushioning elements may include several layers of fabric or relatedmaterials quilted together or it may merely be a single textile itemfashioned so as to encase fully or partially the core elements of themattress.

It is important to note that the nested, zipperless ticking assemblydepicted in the present disclosure is an integral part of the mattressand is not something that is added on to a mattress by a consumer at adate subsequent to original purchase.

Federal regulations clearly define what a mattress is and that it issubject to certain testing requirements, including 16 CFR 1633—Standardfor the Flammability (Open Flame) of Mattress Sets. The ticking assemblydepicted herein by the present disclosure is the outermost fabricassembly of the mattress as it is manufactured for sale by the mattressmanufacturer and that is subjected to this testing described above.

In accordance with the definitions found in Section 2 of the FlammableFabrics Act as amended (15 U.S.C. 1191) and 16 CFR 1633 Standard for theFlammability (Open Flame) of Mattress Sets, it has been discovered thata consumer-removable, nested, zipperless mattress ticking assembly candeliver a variety of benefits not heretofore provided in mattressdesign.

It fully anticipated by the present disclosure that the textile examplerecited herein should not be limited to the particular fabrics describedand that any materials or fabrics customarily or reasonably employed inthe manufacture of mattresses or articles of upholstered furniture maybe utilized to derive the benefits of the present disclosure.

Traditionally, ticking fabrics for mattresses have been yarn-basedtextiles that have been woven or knitted and form the outer surface ofthe mattresses. Woven fabrics have historically been used on innerspringmattresses, however the use of knitted fabrics as tickings has increasedin concert with the increase of non-innerspring mattresses and the useof expensive, high quality cushioning materials whose comfort benefitsare diminished or hidden by woven fabrics and promoted and enhanced byknits. Woven fabrics are limited in their ability to stretch andrecover, whereas knitted fabrics provide stretch and recovery propertiesafter compression to provide support that conforms to the use ofresilient cushioning materials in the mattress core assembly. Thecomplete range of woven structures is anticipated, including, but notlimited to simple and compound weaves, plain weaves, oxfords, taffetas,dobby weaves, drill, twill, gabardine and the like and these fabrics mayalso be greige, finished, uncoated or coated. Such ticking materials maybe suitably employed in the various embodiments of the presentdisclosure.

Because of fire performance requirements, a fire-resistant barriermaterial may be laminated to the inner surface of the selected tickingfabric or integrated in production to the ticking fabric. Alternatively,a fire-resistant ‘sock’ or sleeve component comprising a two-dimensionalstretchable knit may be placed over the mattress core during assemblyand the ticking fabric without flame resistant enhancement is placedover the knitted fire-resistant sock. Ticking fabrics may also bequilted with fibers or foams to augment their comfort and aestheticprofiles.

As is necessary now in mattress construction to ensure compliance withfull-scale fire testing requirements, such as 16 CFR 1633, mattressesare protected by fire barriers or fire blocking systems. These firebarriers or fire blocking systems can take a variety of forms and in theinterest of clarity and simplicity for communicating the fundamentaldesign elements of the present disclosure, the specific nature of thefire barriers or fire blocking systems have not been explicitly shown inthe drawings contained herein.

The fire barriers or fire blocking systems are most typically textilebased structures. Knitted fabrics, woven fabrics, non-woven fabrics, andother similar yarn or fiber-based, inherent flame retardant orchemically treated or processed textiles and combinations thereof arethe most commonly used means of delivering fire blocking performance tomattress or upholstered furniture constructions. The fire barrier orfire blocking systems can be used to independently encase the internallydisposed cushioning elements of a mattress or upholstered furniturearticle or they may be integrated directly into the ticking textilesused to construct the outermost fabric used to construct such items. Thepresent disclosure is contemplated to be able to accommodate allapproaches presently used to deliver fire blocking performance to thedesign of mattresses and upholstered furniture articles.

Exemplary fibers used in the textiles formed for use as tickings or firebarriers may include organic, natural, man-made or synthetic materials,including but not necessarily limited to cotton, nylon, rayon, wool,linen, silk, acrylic, olefin, polypropylene, polyesters, bi-componentpolyesters and elastomeric materials.

More specific examples for materials for us in fire barriers includearamids, including para-aramids (poly(p-phenylene terephthalamide),e.g., KEVLAR® (E. I. Dupont) and TWARON® (Teijin Twaron BV) andmeta-aramids (poly(m-phenylene isophthalamide), such as Nomex® (E.I.Dupont); fiberglass; melamines such as BASOFIL® (BASF);poly-benzimidazole (PBI) (Celanese Acetate A.G); oxidizedpolyacrylonitrile (PAN); novoloids, such as KYNOL®. (American Kynol,Inc); pre-oxidized fibers and carbon fibers, modacrylics, such as, e.g.,KANECERON® and PROTEX® (Kaneka), FR (fire- or flame-resisting,-resistant, -retarding or -retardant) rayon, FR viscose, such as, e.g.,VERIFIBER® TCF FR Rayon (Ventex, Inc.) and LENZING FR® (Lenzing AG,Fibers Division), wool and FR-treated cotton. It should be noted thatthese fibers are merely exemplary, and other fire-retardant fibers thatform a char, including fibers that are developed in the future may beused. Additionally, certain proprietary modacrylic fibers that releaseextinguishing/oxygen depriving elements such as antimony when exposed toan ignition source may be used. This chemical reaction may assist insnuffing out small flames that may occur on adjacent, non-FR componentssuch as the mattress covering fabric or ticking. Blends that include atleast one fire-retardant fiber that form a char may also be used. Theblends may include one or more structure-providing char-formingfire-retardant fibers, FR-treated fibers, such as FR-treated polyester,and non-FR fibers. Accordingly, either the fibers themselves may have achemical structure that provides flame retardant characteristics or thefibers may include an additive that separately provides flame-retardantcharacteristics. Such additives may specifically serve to coat thefibers and provide a surface treatment and/or be dispersed within agiven fiber network. Exemplary additives include polyphosphate compoundsincluding polyphosphate emulsions, inorganic salts, aluminum oxides(e.g. Al2O3), boric acid compounds and/or halogen compounds.

The fire barrier element of the mattress may be provided by woven,knitted textile or non-woven. Examples of possible woven structures havebeen provided herein, and the types of knitted structures may includecircular and warp knits, weft inserted knits, rib knits, jersey knits,interlock knits, double-knits, fleece knits, velour knits,

Non-woven fabrics may utilize a number of methods for maintaining thefibrous structures as well as joining more than a single fabric layer.Exemplary chemical bonding methods may include the use of adhesives,such as adhesive fibers, bi-component fibers or adhesive coatings thatmay be applied via powder coating, spray coating, baths, etc. Exemplarythermal bonding methods may include the use of low melting point fibers,bi-component fibers, point bonding, ultrasonic bonding, etc. Exemplarymechanical bonding may include carding, needle-punching, air-jetbonding, water-jet bonding, etc. In addition, the non-woven fabric foruse may be three-dimensionally deformed via thermo-mechanical processesto form three-dimensional compressible features.

Further, the nested, zipperless mattress ticking assembly of the presentdisclosure may comprise an elastic fibrous assembly. As used herein theelastic fibrous assembly is the combination of constituent fibers orfibrous components that have been fitted together to form a structurethat exhibit recovery when a mechanical stress is applied to thestructure and subsequently released. In particular an elastic nonwovenstructure or weft-type circular knitted textile structure may be anelastic fibrous assembly. The elastic fibrous assembly may utilize anumber of methods to intermingle elastic materials with fibrous assemblyfire blocking materials. The elastic materials may be impregnated into,disposed or sprayed on, laminated or intermingled with fire blockingmaterials.

Elastic or elastomeric materials used herein may include for example,elastomeric polymers, such as polyurethane, chloroprene, etc.Polyurethane may include spandex fiber which may be understood toinclude segmented polyurethane, Spandex®, Dorlastan®, Lycra®,polychloroprene (a type of synthetic rubber also known as neoprene andother elastomeric type polymers that may include polyisoprene,polybutadiene, polystyrene-butadiene and silicones.

The individual component materials used to construct a mattress may bedrawn from the wide range of compositional and design approachespresently employed in the fields of mattress and upholstered furnituremanufacturing without departing from the benefits being provided by thepresent disclosure. For instance, the use of antimicrobial treatments orfinishes, such as those intended to mitigate or prevent bacterial orfungal growth, to provide odor-control or other similar benefits, onmattresses and upholstered furniture articles, including the fibers,yarns, filling materials, and foams, used to construct the mattresses orupholstered furniture articles would be anticipated by the presentdisclosure Other treatments or finishes, such as those intended tomitigate or prevent staining, soiling, moisture vapor penetration,moisture penetration, fluid penetration, or static electricity buildupare similarly anticipated.

The present disclosure does not seek to limit the myriad of materialsthat may utilized to form the textiles that could be used to fashion anyof the elements disclosed herein. Rather it is anticipated that thedesign approach of the present disclosure is suitably novel and flexibleto employ any fiber, yarn or product derived from such fibers or yarnsto that is known to mattress manufacturers and customarily andreasonably used by mattress or upholstered furniture manufacturers to besufficient to withstand the use demands, regulatory performancerequirements and aesthetic desires of consumers.

In the context of the embodiments of the present disclosure, termsrelating to mattresses are defined in conformity with terms as definedby 16 C.F.R. 1632, and as follows:

(a) Mattress means a ticking filled with a resilient material used aloneor in combination with other products intended or promoted for sleepingupon.

-   -   (1) This definition includes, but is not limited to, adult        mattresses, youth mattresses, crib mattresses including portable        crib mattresses, bunk bed mattresses, futons, water beds and air        mattresses which contain upholstery material between the ticking        and the mattress core, and any detachable mattresses used in any        item of upholstered furniture such as convertible sofa bed        mattresses, corner group mattresses, day bed mattresses,        roll-a-way bed mattresses, high risers, and trundle bed        mattresses. See Sec. 1632.8 Glossary of terms, for definitions        of these items.        -   (2) This definition excludes sleeping bags, pillows,            mattress foundations, liquid and gaseous filled tickings            such as water beds and air mattresses which do not contain            upholstery material between the ticking and the mattress            core, upholstered furniture which does not contain a            detachable mattress such as chaise lounges, drop-arm love            seats, press-back lounges, push-back sofas, sleep lounges,            sofa beds (including jackknife sofa beds), sofa lounges            (including glide-outs), studio couches and studio divans            (including twin studio divans and studio beds), and juvenile            product pads such as car bed pads, carriage pads, basket            pads, infant carrier and lounge pads, dressing table pads,            stroller pads, crib bumpers, and playpen pads. See Sec.            1632.8 Glossary of terms, for definitions of these items.

(b) Mattress Pad means a thin, flat mat or cushion, and/or tickingfilled with resilient material for use on top of a mattress. Thisdefinition includes, but is not limited to, absorbent mattress pads,flat decubitus pads, and convoluted foam pads which are totally enclosedin ticking. This definition excludes convoluted foam pads which are nottotally encased in ticking.

(c) Ticking means the outermost layer of fabric or related material thatencloses the core and upholstery materials of a mattress or mattresspad. A mattress ticking may consist of several layers of fabric orrelated materials quilted together.

(d) Core means the main support system that may be present in amattress, such as springs, foam, hair block, water bladder, air bladder,or resilient filling.

(e) Upholstery material means all material, either loose or attached,between the mattress or mattress pad ticking and the core of a mattress,if a core is present.

(f) Tape edge (edge) means the seam or border edge of a mattress ormattress pad.

(g) Quilted means stitched with thread or by fusion through the tickingand one or more layers of upholstery material.

(h) Tufted means buttoned or laced through the ticking and upholsterymaterial and/or core, or having the ticking and upholstery materialand/or core drawn together at intervals by any other method whichproduces a series of depressions on the surface.” (16CFR1632.2).

(r) Mattress foundation. Consists of any surface such as foam, boxsprings or other, upon which a mattress is placed to lend it support foruse in sleeping upon.” (16CFR1632.8).

Additionally, in the context of the present disclosure, these terms arefurther defined in conformity with terms as defined by the ConsumerProduct Safety Commission, 16 CFR Part 1633, Standard for theFlammability (Open Flame) of Mattress Sets; Final Rule—published in theFederal Register, Mar. 15, 2006.

Another aspect of the present disclosure relates to its use in articlesof upholstered furniture. In the context of the present disclosure,terms relating to upholstered furniture are defined in conformity withterms as defined by the draft language of 16 C.F.R. 1634, as publishedby the CPSC in May 2005, and incorporated in their entirety herein byreference.

Another aspect of the present disclosure relates to its use in otherarticles filled with resilient cushioning materials. In the context ofthe present disclosure, terms relating to filled articles and beddingare defined as follows in conformity with the terms defined by theCalifornia BHFTI draft of Technical Bulletin #604 published Oct. 1,2004, and the ANPR for 16 CFR 1634 Standard To Address Open FlameIgnition of Bedclothes published by the CPSC in the Federal Register onJan. 13, 2005, pages 2514 through 2517, and incorporated in theirentirety herein by reference.

The mattress that is intended to be covered by the ticking assemblydisclosure disclosed herein is not intended to be limited and may be ofany type, dimension, and/or shape. For example, the mattress may be afoam mattress, a coiled mattress, a foam and coil mattress, an airmattress, combinations thereof, or the like. Typically, the mattress issquare or rectangular-shaped and has a thickness ranging from about 4inches to about 20 inches. The length and width can vary depending onthe intended application and typically has a width of about 2 feet toabout 7 feet and a length of about 4 feet to about 10 feet, althoughcustom sizes may require smaller or larger dimensions.

Said mattress while typically being square or rectangular, may also takeany other shape, including but not limited to round, triangular, oblong,trapezoidal, or elliptical.

The interior elements of the mattress, customarily referred to as themattress “core” may be formed of foam or a combination of foam and coilssprings. The foam, in some embodiments, can be a monolithic block of asingle type of resilient foam selected from foams having a range ofdensities (themselves well-known in the art) for supporting one or moreoccupants during sleep. In one embodiment, foam core is made of anyindustry-standard natural and/or synthetic foams, such as (but notlimited to) latex, polyurethane, or other foam products commonly knownand used in the bedding and seating arts having a density of 1.0 to 5.0and 10 to 60 ILD. Although a specific foam composition is described,those skilled in the art will realize that foam compositions other thanone having this specific density and ILD can be used. For example, foamsof various types, densities, and ILDs may be desirable in order toprovide a range of comfort parameters to the end user consumer.Additionally, the combining of individual layers of foam with varying,ascending, descending or undulating densities and ILDs may be deemedbeneficial and are fully anticipated by the present disclosure.Furthermore, in addition to possibly of layering different foams, themattress could be comprised of different blocks of foams with differentcombinations of densities and ILDs. These different blocks could belocated in areas of the mattress that correspond to the areas of supportby different parts of the body that sleeps on the mattress. For instancethe areas of the body that typically require the greatest support suchas the buttocks/hip and the shoulders/torso area could have foam blocksplaced in areas of the mattress where those body parts would be expectedto reside with appropriate densities and ILD combinations, while thebody areas requiring less support could be satisfied with blocksfeaturing densities and ILD designed to match those support andcushioning requirements.

Certain components of a mattress, such as, for example, springs and/or amattress topper may become worn before other components of the mattress.It would thus be beneficial to provide a mattress that allows somecomponents to be replaced without replacing the entire mattress. Indeed,replacing the springs of a mattress, for example, without replacingother components of the mattress would significantly reduce the cost tothe user who would otherwise have to buy a new mattress if the springsbecome worn or otherwise in need of replacement. An additional benefitto be derived from promoting and facilitating the end-consumer's abilityto selectively replace any of the mattress components contained withinthe ticking assembly is that the waste stream impact of product disposalis reduced to only the targeted parts and the remaining parts are givenextended service life.

Accordingly, this disclosure is directed to customizable mattresses thatinclude variable components that allow a sleeper to create a mattressthat has performance characteristics specifically tailored to thesleeper's body type and/or sleep preferences while also allowing thesleeper to replace the variable components with other variablecomponents over time should the variable components become worn and/orthe sleeper's body type or sleep preferences change over time.

Removable ticking assemblies have been employed in the construction ofmattresses, however such assemblies have universally employed zippers asa means to join, attach and close multiple elements of the tickingassembly to one another. The use of zippers in the construction of theticking assembly creates a variety of design deficiencies that areovercome by the present disclosure.

First, zippers of satisfactory quality are expensive. Elimination of thezipper can save money for the manufacturer and the end consumer.

Second, zippers present a potential breach point in the fire protectiondesign of the mattress as they are not typically fashioned from flameresistant materials and those zippers that are so fashioned of flameresistant materials are substantially more expensive than thetraditional zippers that the present design eliminates.

Third, to overcome the breach point of the zipper in the fire protectiondesign, many mattress ticking assemblies that are made with zippersplace a flame retardant fabric flange behind the zipper, however thisflap of fabric is challenging to place correctly to encourage accurateinstallation and preservation of the placement necessary to overcome thebreach point. The present disclosure does not require a flange toprotect the interior mattress elements from ignition sources.

Fourth, zippers are prone to failure as evidenced by more than 7,000videos posted on the YouTube internet video streaming service that offeradvice of how to fix a broken zipper. The absence of the zipper from theticking assembly precludes this potential failure point.

Fifth, the closing of the zipper can be a time-intensive and laboriousprocess for an individual in order to ensure proper alignment andorientation of the zipper as well as the time required to exercise careto ensure that fabric elements of the ticking assembly do not becomesnagged, entrapped or damaged by the zipper closing process. The“pop-on” nature of the present disclosure does not require the end userto line up and slowly and methodically close a zipper and eliminates thepotential for the ticking assembly or user to be damaged or injured bythe zipper closing process.

Sixth, zippers have typically been viewed only as an adjunct part of theproducts into which they are sewn as a result the manufacturers ofzippers have been driven to utilize the lowest cost materials, whichhave heretofore been predominantly polyester. As virtually allmanufactured polyester contains antimony, zippers made from polyestercontain antimony, a known carcinogen, and the elimination of zippers inthe present disclosure serves to be a tool to enable consumers toeliminate the presence of a potentially toxic substance from theirmattresses and by extensions their homes.

Good sleep is widely believed to be critical in enabling people to feeland perform their best, in all aspects of their lives. Sleep isroutinely touted by medical professionals as being essential forimproved health. Good sleep has been shown to affect numerous aspects ofeveryday life, from the ability of students to commit new information tomemory to preventing weight gain. Because of the myriad of importantbenefits to be derived from good sleep, it is essential for people tohave mattresses and bedding that match their personal sleep preferenceand are suited to their body type in order for them to enjoycomfortable, restful, beneficial sleep.

The 2012 “Bedroom Poll” conducted by the National Sleep Foundation(NSF), determined that 92% of nearly 1,500 rated that having acomfortable mattress was an important determinant in getting a goodnight's sleep. Those findings, which can be found at the NSF website,www.sleepfoundation.org, are incorporated herein by reference.

The human body may change over time. Sleeper may lose or gain weight.The change in weight may be slight or significant. When the change inweight is significant, it may affect the type of bedding the sleeperrequires to achieve restful sleep. For example, a significant gain inweight may require that a sleeper use a firmer mattress, to providesupport for the added weight. Conversely, a material weight loss cansimilarly affect the consumer's reaction to the comfort and feel of themattress cushioning elements.

The sleeper's sleep preference may also change over time. For example, asleeper who typically likes to sleep on their back may, over time,prefer to sleep on his or her side. The change in sleep preference mayaffect the type of bedding the sleeper requires to achieve restfulsleep. For example, a sleeper changing from a back sleeper to a sidesleeper may require that the sleeper use a firmer mattress.

The firmness and degree of support provided by a mattress can beinfluenced by the selection of the cushioning materials used to build amattress. In the DTC selling model, the innerspring units historicallyfound in the vast majority of mattresses have been mostly replaced bylayers of foam that have been glued together. The most prevalent type ofcushioning material used is foam, however foams come in a wide range andvariety of compositions and the preparation of the foams can be alteredto deliver differing densities as well as differing levels of firmness.

The Polyurethane Foam Association provides a teaching aid forunderstanding the technical terms related to flexible polyurethane foam(FPF) on their website at http://www.pfa.org/ce/handout2.html and thefollowing definitions are well-known to those skilled in the art. Thesedefinitions have also been widely adopted for referring to the physicalproperties of foams of other compositions including gel foams, syntheticand natural latex foams and blends thereof,

Density—A measurement of the mass per unit volume. It is measured andexpressed in pounds per cubic foot (pcf) or kilograms per cubic meter(kg/m3).

Indentation Force Deflection (IFD)—A measure of the load bearingcapacity of flexible polyurethane foam. IFD is generally measured as theforce (in pounds) required to compress a 50 square inch circularindentor foot into a four inch thick sample, typically 15 inches squareor larger, to a stated percentage of the sample's initial height. CommonIFD values are generated at 25 and 65 percent of initial height.

Support Factor (Compression Modulus)—Support Factor=65% IFD, 5% IFDdetermined after one minute of rest or recovery. When the support factoris known it can be used in conjunction with a known 25% IFD value todetermine the 65% IFD value. Seating foams with low support factor aremore likely to bottom out under load.

Flex Fatigue (Dynamic Fatigue)—A softening or loss of firmness. Ingeneral, fatigue is measured in the laboratory by repeatedly compressinga foam sample and measuring the change in IFD. Several differentprotocols, including methods contained in ASTM, ISO, and BIFMA testingstandards, may be used. Even ASTM 3574, one of the more widely used setsof testing standards, contains multiple testing methods. In selectingone or more test methods, it is important to consider the intended foamapplication and to choose a testing protocol that closely simulates theintended application.

Tear Strength—A measure of the force required to continue a tear in afoam after a split or break has been started and expressed in pounds perinch (lb./in.). This property is important in determining suitability offoam in applications where the material is sewed, stapled, or otherwiseanchored to a solid substance.

Resilience—An indicator of the surface elasticity or “springiness” offoam. It is measured by dropping a steel ball onto the foam cushion andmeasuring how high the ball rebounds.

Hysteresis—Measurement of a foam's ability to maintain original supportcharacteristics after flexing. Normally, the firmness (IFD) is tested at25% indentation, 65% indentation and again at 25% on the way up.Hysteresis is the percent of 25% IFD loss measure as a compressiontester returns to the normal (25% IFD) position after measuring 65%compression. Lower hysteresis values, or less IFD loss are desirable.Current research indicates that hysteresis values may provide a goodindication of overall flexible foam durability. Low hysteresis inconventional foam is equal to less IFD loss in durability and fatiguetests.

Air Flow—Amount of air expressed in cubic feet per minute, that can bedrawn through a 2″×2″×1″ foam sample at 0.5-inch water pressuredifferential. Air Flow is measured by a test. High air flow equates tovery open foam while low air flow tends to be pneumatic. Air flow can bea critical factor in FPF performance depending on the application. Forinstance, in normal furniture cushioning applications, a pneumatic foamwith low air flow will have poor durability and high compression sets,regardless of density. However, in a packaging foam, a foam with minimalairflow may be desirable as a shock absorber, or in medicalapplications, slow recovery foams are used to improve patient care. Lowair flow foams are also used in gasketing applications in airconditioning and heating.

Details on the laboratory procedures used to measure FPF performanceproperties can be found in ASTM 3574, which is incorporated herein byreference, and in other testing standards such as those promulgated byISO and BIFMA. Also, to make a fair comparison of FPF sample properties,the same test methods and testing conditions must have been applied.

Certain materials used in the construction of a mattress, such as, forexample, the resilient cushioning materials (foams) and textilecomponents (such as the tickings and fire barrier fabrics) may wear outover time before some of other materials used to build the mattress. Itwould be beneficial, both from a cost perspective as well as anenvironmental impact perspective, to provide mattress designs that allowsome components to be replaced without replacing the entire mattress.Replacing a foam layer of a mattress that has suffered from bodyimpressions being formed in the foam, for example, without replacingother components of the mattress would significantly reduce the cost tothe user who would otherwise have to buy a new mattress if the foam orcover become worn or otherwise in need of replacement and could notseparately be replaced.

Additionally, a mattress ticking assembly with a modular design approachsuch as that depicted by the present disclosure would afford theend-user with the ability to replace a soiled ticking element withoutdisposing of the entire mattress or entire ticking assembly itself.

The benefits of such a modular design would be a strong selling point tothe DTC selling model and some DTC manufacturers have begun to offerproducts with such modularity focused design attributes.

Additionally the modular nature of said design approach would helpovercome a primary deficiency of the DTC selling model, notably that theconsumer cannot feel or try-out the mattress in advance of purchase. Themodularity aspect permits the end-user, consumer and the mattressmanufacturer to engage in a process to alter the feel of the mattressthrough a variety of change scenarios related to the structural,cushioning elements. One scenario would be the resequencing ofstructural cushioning elements in the mattress from the orientationoriginally provided to the consumer. An alternate scenario would bethrough the introduction of additional, new and possibly dissimilarstructural, cushioning elements to the assortment of structural,cushioning elements than those that were originally provided to theconsumer. A third scenario could be through the removal and replacementof a cushioning element not matched to consumer, end-user comfortpreferences with a cushioning element that is preferred.

The mattress itself is not intended to be limited and may be of anytype, dimension, and/or shape. For example, the mattress may be a foammattress, a coiled mattress, a foam and coil mattress, an air mattress,combinations thereof, or the like. Typically, the mattress is square orrectangular-shaped and has a thickness ranging from about 4 inches toabout 20 inches. The length and width can vary depending on the intendedapplication and typically has a width of about 2 feet to about 7 feetand a length of about 4 feet to about 10 feet, although custom sizes mayrequire smaller or larger dimensions.

Mattresses are regulated by the Federal Government with regards to theirflammability and additionally are subject to numerous state and localregulations with regards to their manufacture, composition andlabelling.

The Federal Flammability Act 16 C.F.R. Part 1632 was originallyestablished to provide a federal flammability standard for beddingmattresses to reduce the chance and size of accidental fires caused by acigarette or some form of smoldering heat source coming into contactwith the bedding mattresses. The Consumer Product Safety Commission(“CPSC”) recognized this flammability standard was inadequate due asignificant number of mattress fires that were the result of some formof open fuel source.

In October 2001, working in conjunction with the National Institute forSafety and Technology (“NIST”), the CPSC issued an advance notice ofproposed rulemaking (“ANPR”) concerning the open flame ignition ofmattresses/bedding to broaden the standard to include some form of openfuel source requirement. These flammability standards were researchedand in 2005 the CPSC issued a notice of proposed rulemaking (“NPR”)proposing a flammability standard based on the NIST research.

The characteristics of mattress/bedding fires and research conducted todevelop the standard are discussed in detail in the NPR, 70 F.R. 2470,incorporated herein by reference in its entirety. The final rule wasenacted in March of 2006 as 16 C.F.R. Part 1633 entitled Standard forthe Flammability (Open Flame) of Mattress Sets (hereinafter the “1633flammability standard”) as published in the Federal Register/Vol. 71,No. 50. Mar. 15, 2006/Rules and Regulations, incorporated herein byreference in its entirety. The 1633 flammability standard applies tomattresses and mattress and foundation sets (“mattress sets”). A“Mattress” is defined as a resilient material, used alone or incombination with other materials, enclosed in a ticking and intended orpromoted for sleeping upon.

In recent years, there has been remarkable growth in the number ofmattress companies that have eschewed traditional approaches ofdisplaying mattresses, allowing customers to evaluate mattress comfortand selling mattresses in “brick and mortar” mattress stores andshowrooms in favor of selling their products over the internet anddelivering the products direct to the consumer (DTC). These mattressesare typically compressed, sealed in plastic to hold the compression,rolled and then stuffed in packaging that permits the mattresses to beshipped by courier services such as United Parcel Service, FederalExpress or DHL. The consumer is responsible for unpackaging the mattressand placing it in their desired sleeping space.

By removing the sales margin of a retailer and removing the distributioncosts associated with the transportation and installation of traditionalmattresses that cannot be compressed, rolled and boxed, the DTC sellingmodel is able to deliver a higher perceived value to the end consumer asmattresses of a specific construction can be sold at prices that aresubstantially lower than those sold through traditional “brick andmortar” selling models. One particularly well-known example of thesuccess of this DTC selling model approach is Casper, the internet-basedmattress company that has grown in less than three years to an estimated$200 million dollars of sales per year on sales of roughly 200,000mattresses per annum. Other examples include Leesa, Tuft & Needle,Cocoon by Sealy, Purple, Yoga Bed, Helix, and Luxi to name a few.Notably all of these manufacturers either use zippers to close theirticking assemblies or employ ticking assemblies that are permanentlyclosed with sewn seams.

The use of zippers adds manufacturing cost that the present disclosureeliminates, the prospect of zipper failure that renders the entireticking assembly worthless and opening or closing time and strugglesthat are not present with the simplified installation profile of thepresent disclosure.

The DTC selling model does not afford the consumer with the opportunityto feel the mattress or personally judge the comfort of the mattressthey are purchasing until after it arrives at their residence, is openedand installed.

In the DTC selling model, consumers are typically given several monthsor more to evaluate the mattress for comfort and satisfaction. If theydecide that they do not like the mattress, they are typically given afull refund and the mattress is donated to a charity by the mattressmanufacturer.

Some mattress manufacturers utilizing the DTC selling model haveattempted to address the reported 10% rejection rate in a variety ofways. Some manufacturers provide the customer with slabs of topper foamor other cushioning materials that are different in feel from themattress's original design and that are intended to be placed on top ofthe actual mattress to alter the feel of the bed. Others, such asNovosbed (www.novosbed.com), attempt to alter the feel of the mattressto satisfy the consumer by providing a foam insert that is put into theinside of the mattress but requires the consumer to install a zipperedexpansion panel to allow the mattress ticking assembly to accommodatethe additional height of the added piece of cushioning.

In addition to the benefits to be derived from the present invention bythe elimination of zippers, preferred embodiments offer additionalbenefits as well, most notably with regards to promoting designs thatfacilitate laundering of the removable, nested, zipperless mattressticking assembly.

Many mattress ticking assemblies use different fabrics on the top andbottom elements of the assembly. In many cases the tickings on the topare predominantly knitted fabrics and the fabrics on the bottom arepredominantly non-woven or stitch-bonded fabrics.

Different textile constructions and compositions respond differently tolaundering factors such as washing temperature, drying temperature,detergent compositions and the like. These factors can affect the degreeto which textiles shrink from their original size, change the feel orhand of the material or negatively impact the performance aspects of thefabrics as it relates to such dimensions as flame retardance oranti-microbial performance. In order to mitigate the potentially adverseconsequences of laundering on the performance attributes of thematerials used to construct the mattress ticking assembly, the materialselection process should be structured to select products that will farepositively when laundered to promote the fullest range of benefitsavailable.

Mattress tickings are likely to become soiled during their service livesby a wide range of substances. Consumers will be inclined to attempt tolaunder these tickings if the design promotes their removal from themattress core assembly, even despite possible warnings by manufacturersagainst laundering.

The laundering process can cause a wide variety of outcomes that wouldbe viewed as adverse by the end-user, consumer. The use of differentfabrics in a traditional ticking assembly made with a zipper may resultin varying degrees of material shrinkage during laundering that maycause a cover to be ill-fitting or non-fitting or non-closeable afterthe laundering process.

Even if laundering is not discouraged by the mattress manufacturer, thephysical size of a ticking assembly that is not able to be physicallyseparated may preclude the ability to fit it into many washing machinesor dyers that consumers have in their homes. The preferred embodiment ofthe present invention is for a mattress ticking assembly that is in two,separate and nested parts. These separate parts are therefore, comprisedof less aggregate material than a complete mattress ticking assemblythat is not fully separable into multiple parts and may be of a sizemore easily accommodated by typical washers and dryers.

It is to be understood that the above description is intended to beillustrative, and not restrictive. Numerous changes and modificationsmay be made herein by one of ordinary skill in the art without departingfrom the general spirit and scope of the disclosure as defined by thefollowing claims and the equivalents thereof. For example, theabove-described embodiments (and/or aspects thereof) may be used incombination with each other. In addition, many modifications may be madeto adapt a particular situation or material to the teachings of thevarious embodiments without departing from their scope. While thedimensions and types of materials described herein are intended todefine the parameters of the various embodiments, they are by no meanslimiting and are merely exemplary. Many other embodiments will beapparent to those of skill in the art upon reviewing the abovedescription. The scope of the various embodiments should, therefore, bedetermined with reference to the appended claims, along with the fullscope of equivalents to which such claims are entitled. In the appendedclaims, the terms “including” and “in which” are used as theplain-English equivalents of the respective terms “comprising” and“wherein.” Moreover, in the following claims, the terms “first,”“second,” and “third,” etc. are used merely as labels, and are notintended to impose numerical requirements on their objects. Also, theterm “operably” in conjunction with terms such as coupled, connected,joined, sealed or the like is used herein to refer to both connectionsresulting from separate, distinct components being directly orindirectly coupled and components being integrally formed (i.e.,one-piece, integral or monolithic). Further, the limitations of thefollowing claims are not written in means-plus-function format and arenot intended to be interpreted based on 35 U.S.C. § 112, sixthparagraph, unless and until such claim limitations expressly use thephrase “means for” followed by a statement of function void of furtherstructure. It is to be understood that not necessarily all such objectsor advantages described above may be achieved in accordance with anyparticular embodiment. Thus, for example, those skilled in the art willrecognize that the systems and techniques described herein may beembodied or carried out in a manner that achieves or optimizes oneadvantage or group of advantages as taught herein without necessarilyachieving other objects or advantages as may be taught or suggestedherein.

While the disclosure has been described in detail in connection withonly a limited number of embodiments, it should be readily understoodthat the disclosure is not limited to such disclosed embodiments.Rather, the disclosure can be modified to incorporate any number ofvariations, alterations, substitutions or equivalent arrangements notheretofore described, but which are commensurate with the spirit andscope of the disclosure. Additionally, while various embodiments havebeen described, it is to be understood that aspects of the disclosuremay include only some of the described embodiments. Accordingly, thedisclosure is not to be seen as limited by the foregoing description,but is only limited by the scope of the appended claims.

This written description uses examples, including the best mode, andalso to enable any person skilled in the art to practice the disclosure,including making and using any devices or systems and performing anyincorporated methods. The patentable scope of the disclosure is definedby the claims, and may include other examples that occur to thoseskilled in the art. Such other examples are intended to be within thescope of the claims if they have structural elements that do not differfrom the literal language of the claims, or if they include equivalentstructural elements with insubstantial differences from the literallanguage of the claims.

1. A mattress assembly comprising: a mattress core assembly having a topside, a bottom side, and a peripherally-extending side disposed betweensaid top side and said bottom side; and a nested, zipperless mattressticking assembly for covering said mattress core assembly, said nested,zipperless mattress ticking assembly comprising: an upper mattressticking assembly comprising a top side extending over said top side ofsaid mattress core assembly and a peripheral portion extending over aportion of said peripherally-extending side of said mattress coreassembly; a lower mattress ticking assembly comprising a bottom sideextending over said bottom side of said mattress core assembly and aperipheral portion extending over a portion of saidperipherally-extending side of said mattress core assembly; saidperipheral portions of said upper and lower mattress ticking assembliesoverlap each other along said peripherally-extending side of saidmattress core assembly; and wherein said mattress assembly meets theflammability standards of the 16 CFR
 1633. 2. The mattress assembly ofclaim 1 wherein said nested, zipperless mattress ticking assembly aloneprovides flame resistant properties necessary for the mattress assemblyto meet the flammability standards of the 16 CFR
 1633. 3. The mattressassembly of claim 1 wherein said mattress core assembly comprises one ormore fire barrier interliners covering said mattress core assemblyprovides flame resistant properties necessary for the mattress assemblyto meet the flammability standards of the 16 CFR
 1633. 4. The mattressassembly of claim 1 wherein said mattress core assembly comprises one ormore fire barrier interliners covering said mattress core assembly andsaid nested, zipperless mattress ticking assembly in combinationtogether are operable to provide flame resistant properties necessaryfor the mattress assembly to meet the flammability standards of the 16CFR
 1633. 5. The mattress assembly of claim 1 wherein said top side ofsaid upper mattress ticking assembly comprises a plurality of textilematerials that are quilted or joined together to form a unitary fabric.6. The mattress assembly of claim 1 wherein said top side of said uppermattress ticking assembly comprises a plurality of fabric layers.
 7. Themattress assembly of claim 1 wherein said upper mattress tickingassembly is thicker than said lower mattress ticking assembly.
 8. Themattress assembly of claim 1 wherein said mattress core assemblycomprises a single foam element.
 9. The mattress assembly of claim 1wherein said mattress core assembly comprises a plurality of foamelements.
 10. The mattress assembly of claim 1 wherein said mattresscore assembly comprises a first upper mattress core assembly disposed ona second lower mattress core assembly, said first mattress core assemblyhaving a first top side, a first bottom side, and a firstperipherally-extending side disposed between said first top side andsaid first bottom side, and a second mattress core assembly having asecond top side, a second bottom side, and a secondperipherally-extending side disposed between said second top side andsaid second bottom side, and wherein said upper mattress tickingassembly covers said first top side, said peripherally-extending sidesof said first and second core, and a portion of the bottom side of saidsecond core adjacent to the peripherally-extending edge.
 11. Themattress assembly of claim 1 wherein said mattress core assemblycomprises three or more mattress core elements comprising flexible foamsarranged so that the IFD values of the flexible foams are sequenced sothat the values on the outer surfaces are lower than the IFD values ofthe inner foam elements.
 12. The mattress assembly of claim 1 whereinsaid mattress core assembly comprises springs.
 13. The mattress assemblyof claim 1 wherein said mattress core assembly comprises fibrous fillingmaterials.
 14. The mattress assembly of claim 1 wherein said mattresscore assembly comprises air-filled bladders or containers.
 15. Themattress assembly of claim 1 wherein said mattress core assemblycomprises fluid-filled bladders or containers.
 16. The mattress assemblyof claim 1 wherein said top side of said upper mattress ticking assemblycovers said upper side of the mattress core assembly, and saidperipheral portion of said upper mattress ticking assembly covers saidperipherally-extending side of said mattress core assembly and only aportion of said bottom side of the mattress core assembly adjacent tothe peripherally-extending side of the mattress core assembly.
 17. Themattress assembly of claim 16 wherein an edge of said peripheral portionof said upper mattress ticking assembly define an opening for receivingsaid mattress core assembly.
 18. The mattress assembly of claim 17wherein said upper mattress ticking assembly and said lower mattressticking assembly are physically attached together.
 19. The mattressassembly of claim 1 wherein said upper and said lower mattress tickingsassemblies cover at least fifty-percent of the surface area of themattress core assembly.
 20. The mattress assembly of claim 1 whereinsaid upper and said lower mattress tickings assemblies cover the entiresurface area of the mattress core assembly.
 21. The mattress assembly ofclaim 1 wherein said peripheral portion of said upper mattress tickingassembly and said peripheral portion of said lower mattress tickingassembly extend along the entire length of said peripherally-extendingside of said mattress core assembly.
 22. The mattress assembly of claim1 wherein said nested, zipperless mattress ticking assembly compriseselastomeric properties.
 23. The mattress assembly of claim 1 wherein atleast a portion of said nested, zipperless mattress ticking assemblycomprises a knitted fabric.
 24. The mattress assembly of claim 23wherein said knitted fabric comprises an elastic polyurethane material.25. The mattress assembly of claim 1 wherein said peripheral portion ofsaid upper mattress ticking assembly comprises an elastic material. 26.The mattress assembly of claim 1 wherein said peripheral portion of saidlower mattress ticking assembly comprises an elastic material.
 27. Themattress assembly of claim 1 wherein said upper and said lower mattressticking assemblies are not connectable to one another.
 28. The mattressassembly of claim 1 wherein said upper and said lower mattress tickingassemblies are releasably attachable to one another.
 29. The mattressassembly of claim 1 wherein said upper and said lower mattress tickingassemblies are fixedly attached to one another.
 30. The mattressassembly of claim 29 wherein said upper and said lower mattress tickingassemblies are at least partially attached to one another with sewnseams, snaps and/or buttons.
 31. The mattress assembly of claim 1wherein said lower mattress ticking assembly covers said bottom side ofsaid mattress core assembly, said peripherally-extending side of saidmattress core assembly, and only a portion of the upper side adjacent tothe peripherally-extending side of the mattress core assembly.
 32. Themattress assembly of claim 10 wherein said bottom ticking covers saidbottom side and said peripherally-extending side of said second mattresscore assembly.
 33. The mattress assembly of claim 32 wherein said bottomticking covers a portion of said first top side of said second mattresscore assembly adjacent to the peripherally-extending side of said secondmattress core assembly.
 34. A mattress assembly comprising: a mattresscore assembly having a top side, a bottom side, and aperipherally-extending side disposed between said top side and saidbottom side; an upper mattress ticking assembly comprising a top sideextending over said top side of said mattress core assembly, aperipheral portion extending over said peripherally-extending side ofsaid mattress core assembly, and a bottom side disposed under a portionof the bottom side of the mattress core; and wherein said mattressassembly meets the flammability standards of the 16 CFR
 1633. 35. Themattress assembly of claim 34 wherein said top side of said uppermattress ticking assembly covers said upper side of the mattress coreassembly, and said peripheral portion of said upper mattress tickingassembly covers said peripherally-extending side of said mattress coreassembly and only a portion of said bottom side of the mattress coreassembly adjacent to the peripherally-extending side of the mattresscore assembly.
 36. The mattress assembly of claim 35 wherein an edge ofsaid peripheral portion of said upper mattress ticking assembly definean opening for receiving said mattress core assembly.
 37. A method forforming a mattress assembly, the method comprising: providing a mattresscore assembly having a top side, a bottom side, and aperipherally-extending side disposed between the top side and the bottomside; positioning a nested, zipperless mattress ticking assemblycomprising an upper mattress ticking assembly and a lower mattressticking assembly over the mattress core assembly, and portions of theupper mattress ticking assembly and the lower mattress ticking assemblyoverlapping each other; and wherein the mattress assembly meets theflammability standards of the 16 CFR
 1633. 38. The method of claim 37wherein the positioning the nested, zipperless mattress ticking assemblycomprises first positioning the upper mattress ticking assembly over thetop side of the mattress core assembly and over a portion of theperipherally-extending side of the mattress core assembly, and secondpositioning the lower mattress ticking assembly over the bottom side ofthe mattress core assembly and over a portion of theperipherally-extending side of the mattress core assembly.
 39. Themethod of claim 37 wherein a portion or portions of the upper mattressticking assembly overlap the lower mattress ticking assembly.